How to Choose the Best T-Shirt Materials for Your Prints

Before bringing your t-shirt designs to life, picking the right fabric to print on is crucial. But you may have some questions. Does fabric weight matter? Should you choose DTF printing, DTG printing, or embroidery? 

In this ultimate t-shirt fabric guide, we’ll discuss the most popular fabrics, different printing methods, and which fabric types work best for each. Plus, we’ll show you how to choose t-shirt materials that exceed your expectations.

Specific fabric qualities are more suitable for certain occasions. For example, heavyweight fabric is great for streetwear style, while athletic wear should be moisture-wicking and lightweight. You may also be interested in how the t-shirt fabric is sourced. In this case, it’s important to think about the production of the materials and environmental impact.

In this article, we’ll explore the most popular fabrics in detail. But first, let’s take a closer look at the key factors to consider when choosing the perfect t-shirt material.

Picking the right t-shirt fabric: 6 factors to consider

Here’s a checklist of the different elements to take into account when deciding which t-shirt materials you should go for.

1. Comfort

Comfort is one of the top priorities for any t-shirt, and it largely depends on the fabric choice. Cotton, for example, is renowned for its soft texture and gentle feel, making it a popular choice for everyday wear. Meanwhile, materials like polyester or nylon may have a slightly synthetic feel, especially when worn in hot weather.

Source: Printful

You should also consider comfort in terms of movement. A fabric with slight stretch, like cotton spandex blends, can offer extra flexibility, making it ideal for active or fitted styles. Ultimately, choosing a comfortable fabric means looking at both fit and feel.

2. Weight

Fabric weight, often measured in ounces per square yard (oz/yd²), affects the thickness and overall feel of a t-shirt. Lighter fabrics offer a breezier, more relaxed feel, perfect for summer or layering under jackets. Heavier fabrics give a more structured look that’s durable and ideal for cooler weather.

Source: Printful

Remember, though, the weight of the fabric doesn’t indicate quality—you can find premium-quality lightweight and heavyweight t-shirts alike. It’s more about the feel and structure of the fabric.

How does fabric weight affect t-shirt designs? Your prints will be more textured on heavier fabrics and more detailed and smooth on lighter fabrics. There’s no good or bad; it all boils down to preference and needs.

3. Durability

Durability is crucial if you want your t-shirts to withstand repeated wear and washing while still looking great. Cotton-polyester blends are popular for this reason. Polyester adds strength and reduces shrinkage while still keeping the fabric soft. 100% cotton, which is soft and breathable, may be more prone to shrinking or fading unless pre-shrunk or treated. T-shirts meant for frequent use or athletic wear benefit from a more resilient fabric.

4. Cost

Cost is another important factor, especially if you have a limited budget. Natural fabrics like organic cotton often come at a premium price due to eco-friendly farming practices. In contrast, synthetic fabrics, like polyester or spandex blends, tend to be more affordable but have a different feel and wear quality.

Source: Printful

If premium t-shirt fabrics like organic cotton are out of your budget but you don’t want to sacrifice comfort, consider cotton-poly blends. These fabrics can be a great middle ground, providing durability and a soft feel at a lower price point.

5. Breathability

Breathability is a particularly important factor in warm-weather or active-use t-shirts. Natural fibers like cotton are the top choice here because they allow air to circulate freely, keeping the wearer cool and comfortable. Synthetic materials like polyester are durable but often less breathable and may retain heat and moisture, which can feel less comfortable in hot conditions.

Source: Printful

For activewear or athleisure, look for moisture-wicking fabrics that pull sweat away from the skin. Some polyester blends have been specially treated to improve airflow and moisture control, making them more suitable for workouts.

6. Eco-friendliness

Eco-friendliness is a feature that’s becoming increasingly important for many of us. Go for fabrics like organic cotton or recycled polyester if you want more eco-friendly tees. When considering t-shirt options, check if your chosen supplier has an eco-friendly product tag to help you narrow your choice. Remember that eco-friendly options tend to cost more—these products are often positioned as premium items.

Source: Printful

Top fabric types

With these elements in mind, let’s look at different t-shirt fabrics, their pros and cons, customization techniques, and more.

1. Cotton

Cotton has been around for thousands of years, and conventional cotton is the most popular fabric in the textile industry. In textile manufacturing, cotton is made from natural fibers spun into yarn.

Source: Printful

Cotton is soft, breathable, biodegradable, absorbent, durable, and affordable. Plus, dyes cling to cotton fibers like bees to honey, making them one of the best materials for t-shirt printing. No wonder it’s our customers’ favorite t-shirt fabric from our catalog.

Source: Printful

Pros and cons of cotton

Cotton is breathable and has impressive moisture-absorbing abilities. This makes it the best t-shirt fabric for hot and humid weather. When you perspire, cotton soaks up that sweat and allows it to evaporate, leaving you feeling fresh as a summer breeze.

Plus, nothing compares to cotton’s softness and versatility. This uber-comfortable material is suitable for any occasion. Cotton is also hypoallergenic, just like silk, bamboo, and eucalyptus. This makes it an excellent option for children’s clothing or anyone with sensitive skin.

Source: Printful

On the flip side, I wouldn’t recommend wearing pure cotton in winter, especially if you plan on sweating. Being stuck in the cold with a wet shirt is not fun. Cotton t-shirts also wrinkle easily, and the fabric is more prone to wear and tear than other synthetic blends. Cotton fabric is also sensitive to color fading. But with proper love and care, you can significantly extend its lifespan.

It’s important to note that cotton clothing can shrink when washed, so make sure to follow the instructions on the fabric label. Pre-shrunk cotton won’t shrink as much.

Check out our Guide to Cotton, Polyester, and Blended Fabrics for a complete comparison between cotton and polyester.

Types of cotton

If you pay attention to fabric labels, you may have noticed that not all cotton t-shirts feel the same. Some cotton shirts may be soft and light, while others are heavier and have a more textured weave. The reason behind this is the production process. This t-shirt material can be classified into four main categories:

• 100% cotton—fabric made with regular cotton, also called carded open-end or COE cotton (this refers to the manufacturing process for spinning raw cotton into the yarn used for making t-shirts and other garments). A regular cotton t-shirt is thicker, heavier, and not as soft, making it the right t-shirt material for casual wear or streetwear. It’s also the cheapest type of cotton because the production costs are the lowest.

Source: Printful

• Ring-spun cotton—traditionally produced by wrapping cotton bundles around a spindle and tying them tightly, producing a softer, smoother t-shirt fabric than COE cotton. It’s only slightly more expensive, and the softness and quality upgrade is worth the investment. It’s also about the same weight as regular cotton, so you’re getting more softness with the same insulation.

Source: Printful

• Combed ring-spun cotton—during the manufacturing process, the cotton is literally combed for impurities, removing any short fibers that stick out of the yarn, making it silky soft on the skin. This process results in the highest quality and most expensive cotton. The only thing to consider regarding sustainability is that some of the “impure” cotton fibers get discarded during the combing process. But, because of the high-quality yarn this process produces, combed cotton garments tend to last longer.

Source: Printful

• Organic cotton—the best choice if eco-friendliness is important to you. Organic cotton crops aren’t genetically modified, and there are no pesticides or chemicals that can harm the environment and cause hazardous working conditions. Organic cotton can also be ring-spun and combed. So, you don’t have to sacrifice comfort and quality when choosing more ethical cotton t-shirts.

Source: Printful

Check out our Sustainable Fabrics Guide for more information on this topic, including alternatives to conventional cotton. 

Customization options for cotton t-shirts

Cotton t-shirts are highly versatile and work well with various customization techniques. Here are 3 options to consider:

• Direct-to-garment (DTG) printing—ideal for colorful, detailed designs on natural materials like cotton, thanks to its ink absorption capabilities.

• Direct-to-film (DTF) printing—works on a wide range of fabrics, including cotton, with vibrant colors and versatility for dark or light garments.

• Embroidery—perfect for cotton’s tight weave, creating long-lasting designs that add texture and a premium feel to any t-shirt.

Valuable reads:

• Polyester vs. Cotton Shirts—Pros, Cons, and Printing Options

• 9 Best Cotton T-Shirts: Men’s, Women’s, and Unisex

2. Polyester

Polyester, shortened from its technical name, polyethylene terephthalate (PET), is the most popular synthetic fabric in the world. It’s a kind of plastic made from petroleum—a natural, non-renewable resource. The good news is that polyester fabric can be made from recycled plastic too.

Source: Printful

Polyester is lightweight, extremely durable, and won’t fade or shrink over time if you take good care of it. It’s not elastic in and of itself, but when mixed with other materials like elastane, it can create that perfect stretch. Polyester is still breathable, just not as much as cotton.

Pros and cons of polyester

Polyester is wrinkle-resistant, which makes it a sneaky, convenient way to avoid ironing your t-shirts (a chore few of us enjoy). Another awesome feature is how fast polyester dries. The fabric won’t wear or tear over time if made with high-quality thread. This makes polyester t-shirts easy to care for and a great option for athletic wear.

Another feature that makes polyester ideal for sports is its moisture-wicking properties. A polyester t-shirt traps sweat against the skin and allows it to evaporate instead of absorbing it into the fabric. This means you stay dry and comfortable during physical activity.

Source: Printful

Of course, like other t-shirt fabrics, polyester also has flaws, especially if you care about eco-friendliness. Polyester is non-biodegradable, meaning your t-shirt can take up to 200 years to break down. Also, polyester manufacturing relies on fossil fuels and requires a lot of chemicals.

|Recycled polyester is made by melting old plastic and spinning it into new polyester fiber. It takes five plastic bottles (that would otherwise end up in a landfill) to make one t-shirt. 

Lastly, polyester isn’t great for sensitive skin as it can cause irritation in some cases.

Customization options for polyester t-shirts

The biggest distinction in terms of t-shirt designs is that polyester, or polyester mixed with other synthetic fibers, is the only fabric that works with sublimation or all-over printing. So, if you go for polyester t-shirts, your customization choices are:

• DTF printing—an excellent choice for polyester as it allows for bold, vibrant colors on both light and dark fabrics.

• Embroidery—polyester’s durable, smooth texture works well with embroidery, especially when using a thicker fabric.

• All-over printing—a technique that allows you to print your design all over a garment. The ink used in sublimation doesn’t bond with natural fibers like cotton, so polyester fabric is the best choice for these designs.

Read more:

• What Is Sublimation Printing and How Does it Work?

• Step-by-Step Guide on How to Create Sublimation Designs

3. Fabric blends

Blending multiple fabrics is an excellent way to create a new type of textile with unique properties. Most clothing nowadays is made from a combination of different fabrics. So, no t-shirt fabric guide would be complete without mentioning the most common blends.

Textile scientists started blending fabrics on a large scale in the 1980s. Their goal was to produce the most comfortable material for every occasion. Blending fabrics can improve their texture and durability, creating the perfect canvas for unique prints.

Source: Printful

Pros and cons of fabric blends

The pros of blending synthetic material with natural fibers include more breathability, fewer wrinkles, better insulation, and reduced costs. Blends also dry quicker than pure cotton t-shirts. Combining multiple fabrics can also improve their texture. For example, blending rayon with cotton improves its softness and luster, which enhances its appearance and feel.

Source: Printful

When it comes to print designs, blended fabrics can yield interesting cross-dye effects. One material may absorb the dye vibrantly, while the other fabric retains its natural color. This can be a plus or a minus, depending on your artistic vision.

On the other hand, adding synthetic fiber to natural materials will reduce their natural properties, like being hypoallergenic. It’s also important to note that blending fabrics can add complexity to their maintenance and washing.

Types of fabric blends

Blended fabrics usually contain two or three different fibers (the latter are called tri-blend fabrics). Each fabric also comes in varying ratios—the most common composition for polyester and cotton blends is 65% to 35%, respectively.

Here are the most popular blended fabrics:

• Tri-blend—the most common tri-blend is a polyester-cotton-rayon blend (50/25/25). Rayon is a semi-synthetic fiber made from natural sources of regenerated cellulose, like wood. It’s also called viscose, and depending on the grade, it can resemble natural fibers like silk, cotton, wool, and linen. That’s why it’s sometimes called artificial silk. Tri-blend is ideal for easy-fitting apparel and is loved for its cozy feel. Thanks to the loose weave and combination of fibers, it’s perfect for creating DTG prints with a vintage vibe.

Source: Printful

• Polyester and spandex blends—polyester has no natural stretch, so you won’t find many 100% polyester t-shirts in our catalog. However, spandex, also called elastane or lycra, is a synthetic fiber famous for its elasticity. Adding a bit of spandex to polyester helps create silky smooth, durable t-shirts that are also movement-friendly and stretch-resistant. It’s a great mix for activewear.

Source: Printful

• Cotton polyester blend and others—you may have noticed that gray clothes are more comfortable. If you look closely, the gray fabric is usually a mixture of different fibers with varying color grades. This is called melange, or heather fabric, and it gives a shimmering, mottled color effect.

Customization options for blended t-shirt fabrics

With blended fabrics, you can combine the comfort of natural fabrics with the durability of synthetics. This means you also get plenty of options for customization methods:

• DTG printing—works effectively on cotton-poly blends, creating soft, vibrant prints that bond well with the fabric.

• DTF printing—ideal for blended fabrics, providing bold, durable colors on light and dark garments alike.

• Embroidery—holds up well on blended fabrics like cotton-poly, which provide a smooth, durable base for embroidery, adding a textured, premium look to your designs.

4. Linen

Linen is rarely used as t-shirt material, but it’s a popular choice for dress shirts, especially in the summer. Like cotton, linen is a natural fabric made from the fibers of the flax or linseed plant.

Linen is a durable fabric that is highly absorbent and can dry faster than cotton. In addition to that, it’s also breathable, making linen a top summerwear choice. Linen tends to be more expensive than cotton because the harvesting and weaving process takes longer.

Pros and cons of linen

As a lightweight, breathable, durable fabric, linen is perfect for summertime when temperatures rise and we sweat more. Its natural fibers wick moisture away from the skin, keeping the wearer cool and comfortable even in hot weather. Linen’s textured look also gives shirts a unique, relaxed aesthetic that’s hard to replicate with other fabrics.

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However, linen does come with some downsides. It tends to wrinkle easily, which can make it look more casual or unpolished in certain settings. This also means it's rarely used as fabric for t-shirts. Additionally, linen is less flexible and soft compared to fabrics like cotton, meaning it may feel stiffer against the skin, especially before it's broken in.

Customization options for linen shirts

While linen offers a unique, breathable texture perfect for warm-weather wear, its properties mean that some customization techniques work better than others:

• Screen printing—works well on linen due to its textured surface and strong natural fibers. Although prints may not appear as bold as on smoother fabrics, screen printing offers a durable, slightly faded look that complements linen’s casual, rustic feel.

• Embroidery—linen’s sturdy weave makes it a great base for embroidery, adding a touch of texture and craftsmanship to designs. Embroidery works well with the fabric’s natural aesthetic, giving linen shirts a refined, high-quality finish.

5. Flannel

Like linen, flannel is more known as an excellent fabric for shirts rather than a t-shirt material. But it’s still worth mentioning here to help you understand how this popular shirt material differs from others.

Flannel is a soft, woven fabric typically made from cotton, wool, or synthetic blends. Flannel is known for its cozy, brushed texture, making it perfect for cooler weather, and flannel shirts are often used as layering pieces together with t-shirts.

Flannel is often associated with classic plaid patterns, but remember that not all plaid clothing is made of flannel, and, conversely, not all flannel pieces are plaid.

Pros and cons of flannel

Thanks to its warmth and brushed texture, flannel is a soft, cozy fabric perfect for cooler temperatures. Flannel traps heat while remaining breathable, making it ideal for layering. Its distinct look, which often features classic plaid patterns, adds a rustic, casual aesthetic to any garment.

Source: Pexels

However, flannel does have some downsides. It’s thicker and can feel heavier than standard t-shirt materials, which may make it less versatile for year-round wear. Flannel is also prone to pilling over time, especially with frequent washing.

Customization options for flannel shirts

Due to its thicker, textured surface, flannel works best with customization methods that accommodate its unique characteristics:

• Screen printing—works effectively on flannel, especially for bold, simple designs. The thicker fibers hold ink well, creating long-lasting prints that withstand repeated wear and washing.

• Embroidery—embroidered designs stand out well on flannel, adding a textured, premium look.

Choosing the perfect material

Each fabric in this t-shirt material guide has unique properties—some great, some less so. We’ve discussed multiple factors to help you choose the best t-shirt material for your prints. Remember to consider the fabric quality, feel, and thickness, as well as whether it’s wrinkle-resistant, movement-friendly, breathable, etc. Go for organic or recycled materials if you want something more eco-friendly.

You’ll also want to consider the customization method you want for your designs. Cotton or poly-cotton blends with a high percentage of cotton work nicely with embroidery and offer the highest color vibrancy for DTG or DTF printing. Tri-blend fabrics are awesome for vintage-looking DTG prints, while polyester was born for sublimation printing. And don’t forget that DTF, DTG, and embroidery also work on fabric blends.

I hope this t-shirt material guide leaves you equipped with all the knowledge you need to make the best choices for your t-shirt designs. Whatever the occasion, we’re here to help you find the most suitable t-shirt fabric for your prints.