Cotton vs. Polyester: Which Fabric Works Best for Custom Tees?

Introduction: The Fabric Behind Every Perfect Tee

When it comes to creating high-quality custom t-shirts, choosing the right fabric material is just as important as your design. The debate between cotton vs. polyester has been around for decades — both fabrics dominate the custom apparel world, but each has unique advantages depending on your goals, budget, and print method.

Let’s break down which t-shirt material truly works best for custom shirt printing in 2025.

Cotton T-Shirts: The Classic Choice

Cotton is the go-to choice for comfort lovers. Made from natural fibers, it’s soft, breathable, and ideal for all-day wear.

✅ Pros:

• Soft & breathable: Perfect for warm climates and sensitive skin.

• High print quality: Works great for DTG (Direct-to-Garment) and screen printing.

• Eco-friendly options: Organic cotton and combed ringspun cotton offer sustainable choices.

⚠️ Cons:

• Can shrink after washing if not pre-shrunk.

• Absorbs moisture — less ideal for sportswear.

Best for:
Everyday wear, promotional shirts, premium lifestyle tees.

Polyester T-Shirts: The Performance Powerhouse

Polyester is a synthetic fabric known for its durability, moisture resistance, and color retention. It’s the top pick for sportswear brands and activewear lines.

✅ Pros:

• Moisture-wicking: Keeps sweat away, ideal for athletes and outdoor wear.

• Durable & wrinkle-resistant: Holds shape even after multiple washes.

• Vibrant prints: Works best for sublimation printing — designs never crack or fade.

⚠️ Cons:

• Less breathable than cotton.

• Can feel less natural or soft depending on the weave.

Best for:

Activewear, uniforms, branded merchandise, sublimation printing.

Cotton-Poly Blends: The Best of Both Worlds

In 2025, more brands are turning to cotton-polyester blends for a balance of comfort and performance.
For example, a 60/40 cotton-poly mix offers softness with added durability — perfect for custom tees that last.

Benefits of Blended Tees:

• Softer than pure polyester, stronger than pure cotton.

• Less shrinkage and better color retention.

• Works well for both screen printing and DTG printing.

Best for:

Daily wear, company uniforms, branded fashion lines, wholesale apparel.

Choosing the Right Fabric for Printing

Your printing method affects which material performs best:

Final Verdict: Which One Wins?

If your focus is comfort and natural feel, go with cotton tees.
If you need durability and performance, choose polyester.
And if you want a balance of both — cotton-poly blends are your best bet for custom shirt quality that lasts.

At CoolCustomize, we use premium cotton and polyester blends designed for high-quality printing and long-lasting comfort. Whether you’re a brand, team, or reseller, our custom t-shirts bring your design to life — with wholesale pricing, no minimum orders, and worldwide shipping.