Shirt material types: Choosing the best fabric for your needs

Choosing the right shirt material for your clothing brand is essential for comfort, style, and durability. 

This article explores popular t-shirt materials, including cotton, polyester, linen, and blends, highlighting their advantages and ideal uses. 

Understanding these fabrics will help you select the best t-shirt material for your needs, whether you seek breathability for summer wear, wrinkle resistance for travel, or a blend of both for everyday comfort.

Main takeaways from this article:

• The different t-shirt material types include cotton, linen, polyester, twill, cotton/polyester blended fabrics, flannel, and corduroy.

• Fabric weight, measured in GSM, impacts the t-shirt's suitability for different weather conditions and activities. 

• The fit of a t-shirt is influenced by the fabric's stretch and construction. A well-fitted t-shirt enhances both comfort and style, so it's essential to consider fabric elasticity.

• High-quality fabrics, such as combed cotton or blends, offer better longevity. They maintain their shape and color over time, ensuring value for money.

• Sustainable fabrics like organic cotton and recycled polyester minimize environmental impact, supporting eco-friendly practices and promoting a healthier ecosystem.

Discover the top t-shirt fabrics to elevate your wardrobe. Learn about these popular materials to choose the perfect t-shirt for comfort, style, and longevity.

Cotton

Cotton fabrics are natural. They come in several main varieties that vary in softness, comfort, durability, and sustainability. Cotton has the advantage over other t-shirt fabrics in softness, comfort, environmental friendliness, cost, and t-shirt printing options.

Cotton's main weaknesses stem from its tendency to hold moisture. Cotton can take a long time to dry. It tends to wrinkle and shrink and fades in color over time.

Cotton t-shirts can be made from several types of cotton, including:

• Ringspun cotton: Ringspun cotton goes through a spinning process that straightens, thins, and softens each fiber. This makes it softer, more durable than regular cotton, and more expensive.

• Combed and ringspun cotton: Combed and ringspun cotton adds a combing process to ringspun cotton. This removes impurities and makes the material even softer and less likely to fray or unravel. It also creates a smoother surface for printing designs. The additional processing increases the cost, making it more expensive than ringspun cotton.

• Organic cotton: Organic cotton uses sustainable production methods, avoiding toxic pesticides and synthetic fertilizers. It offers an eco-friendly alternative to regular cotton that can be even softer and more durable. It costs more than standard cotton.

• Slub cotton: Slub cotton is produced with knots and twists, giving the fabric an uneven look and feel. This creates an appealing appearance and texture, making t-shirts more breathable and reducing cling. Slub cotton costs slightly more than regular cotton.

• Pima cotton: Pima cotton has a longer fiber than other types of cotton. This gives it an ultra-smooth, ultra-soft feel, along with resistance to wrinkling and fading and longer durability. Pima cotton is considered one of the highest quality kinds of cotton, making it more expensive.

• Pique cotton: Pique cotton uses a weaving style that gives fabric raised designs in parallel cords or geometric shapes. This creates a textured look and feel along with durability. Pique cotton often serves as fabric for polo t-shirts. It can be woven from Pima cotton. It costs more than some other types of cotton.

Pros

Cotton offers several advantages that help make it one of today's most popular t-shirt fabrics:

• Cotton t-shirts feel soft to the touch.

• T-shirts made of cotton are comfortable to wear.

• Cotton feels gentle against the skin.

• Cotton t-shirts breathe and don't cling.

• A cotton t-shirt is heavier than a polyester t-shirt, a pro for users who want a heavy shirt.

• T-shirts made from cotton are durable.

• Cotton is biodegradable, and organic cotton is especially eco-friendly.

Cons

• Cotton t-shirts hold moisture, making them slow to dry.

• T-shirts made of cotton can be more prone to wrinkle and shrink, although preshrinking can reduce this risk.

• Colors on cotton t-shirts tend to fade over time.

• Cotton t-shirts are easier to stain and damage.

• For wearers who want a lighter shirt, the weight of cotton can be a con.

Polyester

Polyester is a synthetic fabric, usually made from plastic. It repels water and moisture, making it quick to dry and resistant to stains, odors, wrinkles, and shrinking. Polyester is also moisture-wicking, moving sweat away from the skin to a t-shirt's surface, where it evaporates quickly.

Polyester t-shirts cost more than cotton t-shirts. They don't breathe as well as cotton t-shirts, and they pick up static easily, making them prone to cling. Some wearers find polyester irritating to their skin. Polyester is not biodegradable. Polyester t-shirt material works better with direct-to-garment (DTG) and sublimation printing methods than silk screening.

Pros

• Polyester's moisture-wicking properties help move sweat away from the body.

• Polyester t-shirts dry quickly.

• T-shirts made from polyester don't absorb stains and odors as easily as other fabrics.

• Polyester t-shirts resist wrinkling and shrinking.

Cons

• Polyester t-shirts cost more than cotton shirts.

• T-shirts made from polyester don't breathe as well as cotton shirts.

• Polyester t-shirts tend to cling.

• Polyester can irritate some people's skin.

• T-shirts made from polyester aren't biodegradable.

• Silk screen printing can be hard to apply to polyester.

Cotton/polyester blended fabrics

Cotton/polyester blended t-shirts combine some of the benefits of cotton and polyester while facing some of the same limitations as polyester. Like cotton, they're soft and comfortable. Like polyester, they're quick-drying, resistant to wrinkles and shrinking, and durable. They cost less than pure polyester.

However, cotton/polyester blends can cling and irritate the skin like polyester. They support a more limited range of printing options than cotton and cost more. Blends with high cotton content may be more prone to shrink than pure polyester.

Cotton/polyester blend t-shirts come in several varieties, each with its own characteristics:

• 90% cotton/10% polyester: Containing predominantly cotton content, this poly/cotton blend is soft and breathable. It is less prone to shrink than pure cotton but less shrink-resistant than high-polyester blends.

• 65% polyester/35% cotton: This is the most popular blended t-shirt fabric. It contains enough polyester to deliver the shrink resistance of that material but enough cotton to offset polyester's higher cost. However, it still costs more than pure cotton, and its polyester content is high enough to cause clinging, promote skin irritation, and limit printing options. This blend is widely used for sports and exercise.

• 60% polyester/40% cotton: A variation on 65%/35% blends with less polyester and more cotton than that blend, making it more prone to shrink while lowering costs.

• 50% polyester/50% cotton: Half-polyester, half-cotton blends are more breathable than 65%/35% blends, making them popular for sports and exercise.

• 52% cotton/48% polyester: This variation in the 50%/50 % blend with slightly more cotton. It makes the fabric more breathable while cutting costs.

• 25% cotton/50% polyester/25%: The rayon (tri-blend) splits cotton's share of the mix with rayon, a semi-synthetic fiber made from cellulose sources such as wood pulp. Some types of rayon imitate the properties of silk, providing t-shirts with a smooth feel and drape-like fit. Tri-blend shares the advantages of cotton and polyester, but they can cling and irritate the skin like polyester.

Fabrics with 65%/35% and 50%/50% compositions are the most common cotton/polyester blends for t-shirts.

Pros

• T-shirts made from cotton/polyester blends combine some of the strengths of both fabrics at a lower price than pure polyester.

• Blended-fabric t-shirts offer the softness and comfort of cotton.

• Blended-fabric t-shirts dry quickly, resist shrinkage, and provide durability like polyester.

Cons

• T-shirts made from cotton/polyester blends cost more than pure cotton.

• Blends with high cotton content may shrink.

• Blended fabrics aren't biodegradable.

• Cotton/polyester blends with high polyester cotton don't work well with silk-screen printing.

Linen

Linen is a natural fabric made from the fibers of the flax plant. Known for its lightweight and breathable qualities, linen is an excellent choice for warm weather. Its distinct texture and slightly crisp feel make it a popular t-shirt choice for casual and summer wear.

Linen t-shirts are an excellent choice for those seeking a blend of comfort, style, and sustainability, especially in warm climates. They provide a unique aesthetic and practical benefits, making them a valuable addition to any wardrobe.

Pros

• Excellent for hot and humid climates.

• It feels airy and comfortable on the skin.

• It is stronger than cotton and lasts longer.

• Absorbs moisture without feeling damp.

• Made from natural flax fibers.

Cons

• Requires regular ironing to maintain a crisp look.

• It's not as flexible as some other fabrics.

• It may shrink if not cared for properly.

• Generally more expensive than other fabrics

Flannel

Flannel is a soft, warm fabric often made from cotton, wool, or synthetic fibers. It is known for its brushed surface, which provides a cozy and comfortable feel. Flannel t-shirts are ideal for cooler weather, offering both style and warmth.

Pros

• Ideal for cooler temperatures.

• Provides a comfortable, cozy feel.

• Long-lasting and resistant to wear and tear.

• Good moisture-wicking properties, keeping you dry.

Cons

• Heavier than other t-shirt fabrics might be unsuitable for warmer climates.

• Prone to pilling over time with repeated washing.

• It may shrink if not properly cared for, especially when exposed to high heat during washing or drying.

• It is less stretchy than other fabrics, which might affect fit and comfort for some people.

Corduroy

Corduroy is a distinctive and durable fabric known for its unique ribbed texture, created by twisted fibers woven in parallel. While traditionally used for pants and jackets, corduroy is increasingly popular in t-shirt designs for its vintage appeal and sturdy construction. The fabric's characteristic ridges, or "wales," give it a plush feel and an eye-catching look, making it a fashionable choice for casual and retro-inspired outfits.

Pros

• Corduroy is a strong and long-lasting fabric, ideal for items that require extra wear resistance.

• The fabric provides excellent insulation, making it a great choice for cooler weather.

• Its unique ribbed texture adds visual interest and a tactile dimension to t-shirts.

• Corduroy has a timeless, retro aesthetic that can add a distinctive flair to your wardrobe.

• With its soft and plush feel, corduroy is comfortable to wear.

Cons

• Corduroy is heavier than many other t-shirt fabrics, which might be less suitable for hot weather.

• It requires more careful maintenance, including avoiding high heat when washing and drying.

• It is less stretchy than cotton or jersey fabrics, which may affect fit and mobility.

• Primarily suited for autumn and winter, limiting its versatility in warmer climates.

Twill

Twill is a versatile and durable fabric with a distinct diagonal weave pattern. Known for its strength and resistance to wear, twill offers a unique texture and appearance. Due to its robust nature and stylish finish, twill is commonly used in various types of clothing, including t-shirts.

Pros

• Twill is highly durable and resistant to wear and tear.

• The diagonal weave helps the fabric resist wrinkles.

• Twill's tight weave makes it less prone to staining.

• Despite its strength, twill is generally soft and comfortable against the skin.

• The diagonal weave pattern provides a stylish, distinct look.

Cons

• Twill can be heavier than other fabrics, which might not be ideal for hot weather.

• It is less breathable compared to lighter fabrics like cotton or linen.

• High-quality twill fabrics can be more expensive than other common t-shirt materials.

Selecting the best t-shirt material involves considering factors like comfort, durability, breathability, and ease of care. By understanding these aspects below, choose a fabric that suits your customers’ lifestyle and ensures your t-shirt products feel great and last a long time.

Comfort

T-shirt fabric comfort refers to how the material feels against your skin. Key factors influencing comfort include softness, breathability, and flexibility. A comfortable fabric should feel gentle, allow air circulation, and offer some stretch to accommodate movement.

To evaluate comfort, consider the fabric's texture and composition. Natural fibers like cotton are typically softer and more breathable than synthetic ones. Try on different fabrics to see how they feel, and choose those that feel most pleasant against your skin.

Weight

T-shirt fabric weight refers to the thickness and heaviness of the material, typically measured in grams per square meter (GSM). Lightweight fabrics (around 100-150 GSM) are thinner and more breathable, while heavyweight fabrics (200+ GSM) are thicker and more durable.

Check the GSM rating and feel the fabric's thickness to evaluate weight. Consider various climates and how (and time of year) your customers will wear the item. Mid-weight fabrics (150-200 GSM) balance breathability and durability for versatile options.

Fit

T-shirt fit refers to how the garment conforms to your body's shape. The fit is influenced by fabric stretch, cut, and construction. A well-fitted t-shirt should complement your body shape without being too tight or loose.

To evaluate fit, consider the fabric's stretchability and elasticity. Fabrics with a blend of spandex or elastane offer better fit and flexibility. Try on different styles and sizes, paying attention to how the fabric hugs your body and allows movement.

Longevity and lifespan

T-shirt fabric longevity refers to how well the material withstands wear, washing, and general use over time. High-quality fabrics maintain shape, color, and integrity longer than lower-quality options.

To evaluate longevity, look for fabrics known for their durability, like combed cotton or blended materials. Check the stitching quality and read reviews about the fabric's performance over time. Investing in higher-quality fabrics can lead to longer-lasting t-shirts.

Cost

T-shirt fabric cost refers to the price of the material and the overall expense of the t-shirt. Fabric costs vary widely based on the type, quality, and brand.

To evaluate cost, compare prices of different fabrics and consider your budget. Look for sales, discounts, and value-for-money options. Assess if the higher cost of premium fabrics is justified by their benefits, ensuring you make an informed decision.

Climate sustainability

T-shirt fabric sustainability refers to the environmental impact of producing and disposing of the material. Sustainable fabrics are made from eco-friendly processes and renewable resources, reducing environmental harm.

To evaluate sustainability, look for certifications like GOTS (Global Organic Textile Standard) or OEKO-TEX. Research the fabric's production process and opt for organic cotton, recycled polyester, or bamboo. If your target audience is eco-focused, prioritize fabrics that are eco-friendly to appease consumers.

Intended use

Considering intended use is crucial because it ensures the t-shirt meets your audience’s functional and aesthetic needs. For example, athletic wear needs moisture-wicking fabrics, while casual wear might prioritize comfort and style.

To evaluate intended use, identify the primary purpose for the t-shirt. Choose moisture-wicking and stretchable fabrics for sports, breathable fabrics for hot climates, and more durable fabrics for workwear. Matching fabric properties to intended use enhances your overall experience.

Print compatibility

Print compatibility refers to how well a fabric holds and displays printed designs. Certain fabrics absorb ink better and maintain print quality longer than others.

Choose fabrics with a smooth surface, like cotton or polyester blends, to evaluate print compatibility. If possible, test a small print sample and consult with printing professionals about the best fabric options for your desired print method, whether screen printing, DTG, or heat transfer.

Gelato makes it easy for you to meet your customer's needs by providing you with high-quality cotton, polyester, and blended t-shirts you can print on demand with our direct-to-garment (DTG) printing services. 

Our network produces customized products in 32 countries, allowing t-shirt creators and ecommerce sellers to scale up their sales and reach customers faster while cutting waste, costs, and carbon emissions. Our selection includes organic cotton t-shirts that are focused on sustainability.

Sign up for Gelato to start printing your designs on the best fabric for t-shirts available today.

How many types of t-shirt fabric are there?

Several types of t-shirt fabrics exist, including cotton, polyester, cotton/polyester blends, linen, bamboo, and tri-blends. Each has unique properties and offers various comfort levels, durability, and suitability.

What material are formal shirts made of?

Formal shirts are typically made of high-quality materials like cotton, linen, or silk. Cotton is preferred for its breathability and durability, while linen offers a lightweight, crisp feel. Silk provides a luxurious, smooth texture. Blended fabrics, combining these materials, are also common for added benefits.

What is the best shirt material for hot weather?

The best shirt material for hot weather is lightweight, breathable cotton or linen. Both fabrics allow air circulation, wick moisture, and keep you cool. Linen is especially effective due to its superior breathability and quick-drying properties, making it ideal for staying comfortable in the heat.

What is the softest t-shirt material?

The softest t-shirt material is typically 100% combed ring-spun cotton. This fabric is known for its smooth texture, breathability, and comfort against the skin. Alternative soft materials include tri-blend fabrics, which combine cotton, polyester, and rayon for an ultra-soft, lightweight feel.

What are high-quality t-shirts made of?

High-quality t-shirts are typically made of 100% cotton, organic cotton, Pima or Supima cotton, and cotton/polyester blends. These fabrics offer durability, softness, and breathability. Look for pre-shrunk and tightly woven fabric options for long-lasting wear and comfort.

What shirt material does not wrinkle?

Polyester is a shirt material that does not wrinkle easily. Its synthetic fibers maintain shape and resist creasing, making it an excellent choice for low-maintenance, wrinkle-free shirts. Polyester blends with other fabrics can also offer similar benefits while enhancing comfort and breathability.

What is the most expensive shirt material?

The most expensive shirt material is often silk. Known for its luxurious feel and sheen, silk is prized for its softness, breathability, and elegance. Other high-cost materials include fine cashmere and certain rare types of cotton, like Egyptian cotton, due to their exceptional quality and rarity.