Polyester
Polyester has become a staple fabric in the apparel industry due to its durability and resilience. While it may not have the centuries-old history of cotton, its rising popularity can’t be ignored. Many retailers and consumers are drawn to polyester for its resistance to wear and tear, making it a strong contender in the fabric market.
What is polyester?
Polyester is a synthetic fiber made from petroleum-based products. Unlike natural fibers like cotton, which are harvested from plants, polyester is entirely man-made. Invented in 1941, it’s often chosen for its ability to retain shape, resist shrinking, and withstand frequent washing without fading.
Since then, polyester has evolved, with options like recycled polyester, made from recycled plastic bottles, becoming more available and offering the same benefits as regular polyester.
How is polyester made?
The polyester manufacturing process begins with refining petroleum to extract chemicals like ethylene. These chemicals are then mixed with alcohol and acid in a process called polymerization, which produces long molecular chains. The result is a plastic-like substance that is melted and extruded into thin fibers. These fibers are spun into threads and woven into fabric.
Modern advancements in textile technology have enabled manufacturers to blend cotton and polyester fibers to create hybrid fabrics that offer the best of both worlds, combining polyester’s durability with the comfort of natural fibers.
Polyester Pros
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Durable
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Moisture-wicking
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Quick-drying
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Wrinkle resistant
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Affordable
Polyester Cons
Cotton
Cotton is among the most popular natural fibers on the planet. It’s known for its comfort and breathability and has been a staple in the apparel industry for centuries. Its natural softness and durability make it a favorite for everyday wear and bedding products like cotton sheets, which are prized for keeping you cool during sleep.
What is cotton?
Cotton is a natural fiber harvested from the seeds of the cotton plant. It’s primarily composed of cellulose, which provides softness and breathability. Cotton is valued for absorbing moisture, regulating temperature, and feeling soft against the skin.
How is cotton made?
The process of creating cotton fabric begins with the harvesting of cotton bolls from the cotton plant. After harvesting, cotton fibers are separated from the seeds in a process called ginning. The cleaned fibers are then spun into yarn, which is woven or knitted into fabric.
Cotton production has evolved over time, with modern techniques improving efficiency and quality. However, the traditional process remains largely unchanged, emphasizing cotton’s long-standing role in textile manufacturing. Additionally, cotton is often blended with other fibers, such as polyester, to improve strength and other properties.
Cotton Pros
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Soft and comfortable
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Breathable
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Hypoallergenic
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Moisture-absorbent
Cotton Cons
Polyester vs. cotton: The ultimate comparison
When choosing between polyester and cotton, it’s important to understand the differences between these two fabrics. Both have strengths and weaknesses, depending on what you prioritize—whether it’s comfort, durability, or ease of care.
We’ll break down the key factors that separate polyester vs. cotton. From how they feel and wear to their breathability, durability, moisture absorbency, and printing suitability, this comparison will help you pick the most suitable fabric for your products.
Feel and wear
Let’s take a closer look at how polyester and cotton perform when it comes to feel and fit.
Polyester is lightweight and has a slightly silkier feel than cotton, making it a popular choice for sportswear. While polyester apparel is great for activities, it tends to trap sweat against the skin. This means polyester shirts may feel slightly clammy in warm weather but help retain warmth in cooler temperatures.
Polyester shirts are generally light and thin, which can cause them to cling to the skin a little. Pure polyester may cause slight irritation for people with sensitive skin, though this is less common when blended with other fabrics.
Cotton is a versatile fiber that can be woven or knitted into many different fabric types, such as denim, flannel, and jersey. Each has its unique feel, but all cotton fabrics are known for their softness and breathability, making them ideal for warm climates and people with sensitive skin.
Additionally, cotton isn’t clingy, so if you’re aiming for a looser fit in your store’s clothing, cotton is the way to go. However, keep in mind that 100% cotton dries slowly, which might make it less suitable for activewear.
When it comes to flexibility, 100% polyester isn’t naturally stretchy due to the lack of elasticity in the fiber. However, polyester can be blended with other stretchy fibers like elastane to give it more flexibility. As for shrinkage, polyester doesn’t naturally shrink and will retain its shape even after considerable wear and tear, bouncing back into form quite easily.
Breathability
One of the key factors to consider when choosing fabrics for your apparel store is breathability. Polyester and cotton perform quite differently in this area.
Polyester is a synthetic material that is not as breathable as natural fibers like cotton. While it’s excellent for moisture-wicking—drawing sweat away from the skin—it can also trap heat, making it less comfortable in hot and humid conditions. This is why polyester is often chosen for activewear, where moisture management is a priority, but it may not be the best option for everyday wear in warm climates.
Cotton excels at breathability. Its natural fibers allow for better airflow, making it ideal for warm weather and people who tend to overheat. Cotton fabrics are light, soft, and comfortable against the skin, so they’re often the go-to choice for t-shirts and casual wear. However, while cotton is breathable, it tends to absorb moisture rather than wick it away, leaving the fabric feeling damp in sweaty conditions.
Both fabrics have their advantages, but when it comes to pure breathability, cotton remains the superior choice.
Moisture Absorbency
When it comes to moisture absorbency, polyester and cotton have very distinct properties that can influence your choice depending on the intended use of the garment.
Polyester is hydrophobic, meaning it repels water instead of absorbing it. This makes it ideal for athletic wear and outdoor apparel, as it doesn’t become heavy or waterlogged when exposed to moisture. Instead of absorbing sweat, polyester wicks it away from the skin, allowing it to evaporate quickly. This moisture-wicking capability is why polyester is a favorite for activewear, keeping the wearer dry and comfortable during physical activity.
Cotton is highly absorbent. It can soak up moisture, which makes it comfortable for everyday wear but less suitable for intense physical activity. While this absorbency can be great for cooling off in warm weather, it can also leave the fabric feeling damp if the wearer sweats heavily. Cotton doesn’t wick moisture away like polyester, so it can retain sweat and take longer to dry. For this reason, cotton is generally better suited for casual wear rather than athletic purposes.
If quick drying and moisture-wicking are priorities, polyester is the better choice. However, for comfort and natural absorbency, cotton excels in everyday wear.
Durability and care
Polyester is known for being extremely durable—more so than cotton and many blended fabrics. One of its key benefits is its resistance to permanent stains, as polyester is less absorbent than most other materials.
Plus, polyester fabric is highly resistant to wrinkling, shrinking, and fading, especially when properly cared for. To extend the lifespan of polyester garments, it’s recommended to machine wash them in warm water with an all-purpose detergent and tumble dry at a low temperature.
Most Printful products come with specific care instructions that you can find on the product pages to ensure longevity.
High-quality cotton is also durable, though less so compared to polyester or cotton/polyester blends. Cotton’s natural fibers make it prone to shrinking when exposed to high temperatures. To avoid this, wash cotton shirts in cold water, use a delicate cycle, and minimize the amount of detergent to preserve the fabric’s integrity. Cotton garments are more prone to color fading over time, so gentle care is essential.
It’s also worth noting that manufacturing techniques can affect how cotton garments feel, even if they’re all made from 100% cotton. This can create a different wear experience, as highlighted in our People Test T-Shirts video.
