Choosing the right T-shirt fabric can make a huge difference in comfort, durability, appearance, and overall value—especially for businesses ordering custom or branded T-shirts. Two of the most popular options are cotton and polyester, but which one is actually better?
The answer depends on how the T-shirt will be used. In this detailed guide, we’ll compare cotton and polyester T-shirts across key factors to help you make the best choice.
Understanding Cotton T-Shirts
Cotton is a natural fibre made from the cotton plant and has been a favourite in clothing for decades.
Advantages of Cotton T-Shirts
- Superior Comfort: Cotton is soft, breathable, and gentle on the skin, making it ideal for everyday wear and warmer conditions.
- Breathability: The natural fibres allow air to circulate, reducing heat build-up and keeping the wearer comfortable.
- Skin-Friendly: Cotton is hypoallergenic and suitable for people with sensitive skin.
- Great for Printing: Cotton absorbs ink well, producing vibrant and long-lasting prints, especially with screen printing and DTG methods.
Disadvantages of Cotton T-Shirts
- Shrinks if not pre-treated or washed incorrectly
- Wrinkles more easily
- Takes longer to dry
- Less resistant to wear and tear over time
Cotton is perfect for casual wear, promotional T-shirts, and comfort-focused apparel.
Understanding Polyester T-Shirts
Polyester is a synthetic fibre made from plastic-based materials and is widely used in performance and workwear clothing.
Advantages of Polyester T-Shirts
- Durability: Polyester is extremely strong and resistant to stretching, shrinking, and tearing.
- Moisture-Wicking: It pulls sweat away from the body, making it ideal for activewear and physically demanding jobs.
- Quick-Drying: Polyester dries much faster than cotton, making it suitable for frequent washing.
- Wrinkle-Resistant: Maintains its shape and appearance even after repeated use.
Disadvantages of Polyester T-Shirts
- Less breathable than cotton
- Can feel less natural against the skin
- Retains odours more easily
- Not as eco-friendly unless recycled polyester is used
Polyester is best suited for sportswear, workwear, and outdoor activities.
Cotton vs Polyester: Head-to-Head Comparison
| Feature | Cotton | Polyester |
| Comfort | Very soft | Smooth but less natural |
| Breathability | Excellent | Moderate |
| Durability | Moderate | High |
| Moisture Control | Absorbs sweat | Wicks sweat |
| Printing Quality | Excellent | Good (method-dependent) |
| Drying Time | Slow | Fast |
| Eco-Friendliness | Biodegradable | Synthetic |
What About Cotton-Polyester Blends?
Blended fabrics (such as 50/50 cotton-polyester) combine the best of both worlds:
- Softness of cotton
- Durability of polyester
- Reduced shrinking and wrinkling
- Better moisture control
Blends are popular for branded workwear, staff uniforms, and promotional apparel.
Which Fabric Is Better for Custom Printing?
The best fabric depends on the printing method:
- Screen printing: Works exceptionally well on cotton and blends
- DTG printing: Best on high-cotton-content garments
- DTF printing: Works on cotton, polyester, and blends
If vibrant prints and comfort are priorities, cotton is ideal. For durability and frequent washing, polyester or blends are better.
Which Should You Choose?
Choose cotton T-shirts if you need:
- Everyday comfort
- Casual or promotional wear
- Breathable fabrics
- Classic look and feel
Choose polyester T-shirts if you need:
- Long-lasting durability
- Workwear or sportswear
- Moisture-wicking performance
- Low-maintenance garments
For most businesses, cotton-polyester blends offer the best balance.
Conclusion
There is no single “best” fabric, only the best choice for your needs. Cotton excels in comfort and print quality, while polyester shines in durability and performance. Understanding how your T-shirts will be used ensures you select the right fabric for long-term value and customer satisfaction.
Whether you’re printing promotional T-shirts, uniforms, or branded workwear, choosing the right fabric is just as important as the design itself.