T-shirts are the staple wardrobe choice of almost every person. That’s why they remain a popular fashion item even in this century. They are also very inexpensive to buy and make for excellent gifting options. Choosing the right fabric type for your t-shirt is essential to making a quality purchase.
Among numerous types of fabric blends in the printing industry, the two leading ones are polyester and cotton. These two fabrics are similar in appearance and durability. However, both have distinct advantages and disadvantages.
Here, we will identify the key distinctions that set these unique blends apart while deducing the ideal option that offers the best of both worlds.
Fabric Material
The type of fabric is an essential factor in choosing the best t-shirt for yourself. Cotton is a widespread choice for t-shirts, as it is cheap and agreeable. Cotton t-shirts are typically more comfortable and breathable in hotter months when it comes to fabric. You can wear it year-round. On the other hand, polyester is more apt to retain its shape.
Cotton is also better for people with sensitive skin and less likely to fade than polyester. Cotton is usually softer. That’s why best for screen printing, unlike polyester. Polyester requires a complex chemical process for screen printing.
Fabric Softness
Regular cotton doesn’t feel as soft as 100% cotton. You can find other variants of cotton for durable and comfortable t-shirts. For example, You can choose ring-spun cotton. It straightens the cotton yarn and is more durable and lighter than regular cotton.
100% cotton t-shirts are also incredibly soft and comfortable. They do not cling to your skin or irritate it. They also tend to be more affordable than their polyester counterparts, but they fluctuate in price.
For even more comfort, opt for organic cotton. This material grows without chemicals.
Cotton does have its disadvantages. This includes post-dry shrinkage, fading, and locking in sweat.
While cotton is all year round fabric, polyester t-shirts become uncomfortable in summer. Moreover, they are not great for outdoor wear. It also tends to shrink in higher temperatures. However, pre-shrunk cotton keeps you cool on warm days.
Fabric Weight
Fabric weight is also important. Cotton and polyester differ significantly in weight. The higher the GSM, the better the fabric is. Choose a lighter-weight fabric for hot days. For colder days or night events, choose a heavier material. The weight of the fabric is also helpful in determining how long the t-shirt will last.
The most common measurement method is the ounces per square yard, which is the weight of one square meter of fabric. The weight also indicates the thickness of the t-shirt, and usually, the most common way to determine the weight is to feel the fabric by hand.
Often, polyester is also blended with other materials to enhance its lightness. While some polyester is made from recycled materials, others are made from a mix of recycled materials, such as polyethylene terephthalate.
Fabric Tenacity
Cotton is a naturally fluffy vegetable fiber extracted from the seed pods of the cotton plant. Cotton fiber is woven into thread or yarn and sewn into a breathable soft fabric.
Generally, polyester is more durable and less likely to wrinkle than cotton or tri-blends. It is also wholly hydrophobic. Unlike cotton, you can wash polyester shirts many times; They won’t lose shape or color.
This makes them perfect for athletic activities. Polyester is also inexpensive, durable, and holds the printed design well. The two disadvantages of polyester are that it is not biodegradable, and its manufacturing requires extensive use of chemicals.
Fabric Cost
One of the most common debates surrounding the choice between polyester and cotton in t-shirts is the price, and choosing a fabric based on your budget is critical. Cotton is much cheaper than polyester but does have a few drawbacks, including post-dry shrinkage, washing color loss, and locking in sweat.
Polyester itself is made mainly from plastic, and most importantly, it is environmentally friendly. You can get it from recycled plastic bottles, and unlike cotton, polyester doesn’t break down easily.
It holds the color longer than cotton, though we agree it doesn’t produce as vivid a color. Polyester is often cheaper than cotton, and some manufacturers use it as a base fabric.
The Printing Process
When choosing a fabric for custom t-shirts for men and women, consider the printing process used. If your t-shirt is manufactured with DTG printing, 100% cotton will work best. Polyester will bleed color during the printing process and won’t cooperate with some printing techniques. Cotton will also hold ink better than poly, so you can be sure your t-shirts will resist the tearing of the hot weather.
While both types are made to resist fading and sweat beads, cotton is considerably more breathable than cotton. On the other hand, polyester is produced through a chemical process and is not a natural fiber. It is also more durable, water-resistant, wrinkle-resistant, and stretchy than cotton.
The Best of Both Worlds
There also exists a third form of a blend that combines the best features of polyester and cotton to produce a hybrid “tri-blend” with a small percentage of rayon added. This combination of fibers offers excellent drape and comfort. Tri-blend t-shirts also feature slight color heathering, making them look vintage and stylish. While they are more expensive than cotton t-shirts, they make both blends meet in the middle to produce the best blend variant in comfort and quality.
A poly-cotton blend is often fashioned into abrasion-resistant fabrics, making it easier to wash and dry. It is also less likely to shrink or lose durability as fast as other fabrics. This makes it an ideal fabric for sportswear and heavy use.
Drawbacks of Cotton-Polyester Blend
While both types of fabric can be used for custom t-shirts for men and women, one should pay special attention to the blend’s material. A cotton/poly blend t-shirt has all of the benefits of pure cotton, including great drape and breathability. However, it has some drawbacks that are largely imposed by polyester, as it is not a wicking material and can’t resist sweat stains. In comparison, cotton provides maximum softness and doesn’t crease as easily. But while cotton is easier to care for, maintains its shape better, and is more absorbent, polyester tends to be more durable and doesn’t fade, shrink, or lose its color over time.
Choosing the Right Blend for Custom T-Shirts for Men and Women
100% cotton T-shirts may also wrinkle and shrink when washed in hot water. That’s why it’s recommended to always look for pre-shrunk labels on cotton t-shirts. The benefits imposed by this blend largely overshadow its shortcomings, and combining the best features of both, cotton-poly blends are easier to wash, more breathable, and will shrink less. Another benefit of the cotton-polyester blend is that it is not as expensive as 100% polyester and lasts considerably longer than cotton-only or poly-only t-shirts.
Thankfully, there are now more cotton/poly blends on the market than ever before, and this new addition to the custom t-shirts for men and women apparel is here to stay.
