Cotton vs. Polyester: Which Fabric is Right for You?

When it comes to choosing the right fabric for your custom merch, the age-old debate of cotton vs. polyester is one of the first decisions you’ll have to make. Whether you’re ordering t-shirts for your team, building a brand, or just want your designs to land perfectly, knowing how these two fabrics stack up can make a big difference.

So which one’s better? The short answer: it depends. Let’s break down the pros, cons, and real-world use cases to help you decide.

Cotton 101: The Natural Favorite

What is cotton?

Cotton is a natural fiber harvested from—you guessed it—the cotton plant. It’s been used for thousands of years and remains one of the most popular fabrics on the planet.

Why people love it:

• Soft & breathable: Feels great against the skin and allows for airflow.
• Hypoallergenic: Less likely to irritate sensitive skin.
• Eco-friendlier: Biodegradable and renewable (especially when organic).
• Prints beautifully: Especially with water-based inks, cotton delivers a soft, consistent print.

Things to keep in mind:

• Cotton can shrink if not preshrunk.
• It tends to wrinkle more easily.
• Not the best for high-sweat activities—it soaks up moisture instead of wicking it away.

Some of our favorite 100% cotton shirts:

Polyester 101: The Performance Powerhouse

What is polyester?

Polyester is a synthetic fabric made from petroleum-based fibers. It’s engineered for strength, durability, and performance—think athletic wear, outerwear, and corporate polos.

Why people choose it:

• Moisture-wicking: Great for keeping you dry during active use.
• Resilient: Resists shrinking, wrinkles, and general wear and tear.
• Dries quickly: Makes it ideal for outdoor or performance-based activities.

Things to watch out for:

• Not as breathable as cotton.
• Can trap heat and odors.
• Made from plastic, so it’s not biodegradable. (*many t-shirts are now featuring recycled polyester in their shirts)

Some of our favorite polyester blend shirts:

Cotton vs. Polyester: A Quick Comparison

Blended Fabrics: Why Not Both?

For many, the sweet spot is right in the middle. Blended fabrics like 50/50 cotton-poly or triblends (usually cotton, polyester, and rayon) offer a little bit of everything:

• The softness of cotton
• The durability of polyester
• A great feel and drape

Blends are especially popular for retail-style t-shirts because they combine comfort, style, and long-lasting wear.

Which One Should You Choose?

Choose cotton if…

You want a soft, breathable, natural feel and eco-friendlier option. Great for everyday wear, fashion brands, and comfort-focused merch.

Choose polyester if…

You need a performance-ready, moisture-wicking fabric that can handle sweat, movement, and repeat wears. Ideal for athletic gear or workwear.

Choose a blend if…

You’re looking for the best of both worlds. Great comfort, great durability, and prints that hold up over time. 

Cotton vs. Polyester: FAQs

No matter which fabric you choose, Real Thread can help bring your vision to life. Our team of experts (yep, real human experts) is here to help you every step of the way. From choosing the right shirt, to making sure your design is justttt right, we've got you covered. Contact us today to get the apparel order of your dreams started.