When planning a custom apparel order, most people start by thinking about design—what colors to use, where to place the logo, or what printing method will work best. But one factor that often gets overlooked is just as important: the garment material itself. The fabric you choose will directly impact comfort, durability, cost, and how well your design prints.
At Company Apparel, we help businesses across San Diego County find the right balance between style, function, and budget. Understanding the pros and cons of popular fabric types—like cotton, polyester, blends, and fleece—can help you make an informed choice for your next project.
Cotton: Classic Comfort and Versatility
Cotton is one of the most popular choices for custom t-shirts, polos, and other apparel. Known for its softness and breathability, cotton garments are ideal when comfort is a top priority.
Pros of Cotton:
- Comfortable and breathable, great for warm climates.
- Natural fibers that feel soft against the skin.
- Excellent for screen printing, producing vibrant colors.
Cons of Cotton:
- Can shrink if not pre-shrunk.
- Tends to wrinkle more than synthetic options.
- Absorbs moisture, which may not be ideal for activewear.
For businesses in San Diego County, where the climate is generally warm and sunny, cotton is a safe and comfortable choice for everyday wear.
Polyester: Durable and Low-Maintenance
Polyester is a synthetic fabric that has become a go-to option for many businesses, especially those looking for performance or workwear.
Pros of Polyester:
- Extremely durable and resistant to shrinking and stretching.
- Retains shape and color, even after multiple washes.
- Quick-drying and moisture-wicking, making it perfect for active settings.
Cons of Polyester:
- Doesn’t feel as soft as cotton.
- Can retain odors if not washed properly.
- May not look as high-end for certain professional settings.
Polyester is especially useful for uniforms that need to hold up under daily wear, such as in hospitality, retail, or active outdoor jobs.
Cotton-Poly Blends: The Best of Both Worlds
Blended fabrics combine the strengths of natural and synthetic fibers. The most common is a cotton-polyester blend, which balances comfort, durability, and cost-effectiveness.
Pros of Cotton-Poly Blends:
- Softer than pure polyester while still being durable.
- Less prone to shrinking and wrinkling than 100% cotton.
- Holds prints well, making it versatile for screen printing, embroidery, or DTF.
Cons of Cotton-Poly Blends:
- Not as breathable as 100% cotton.
- May still absorb odors over time.
Blends are often the sweet spot for businesses that want professional-looking apparel that feels good to wear and lasts through frequent use.
Fleece: Warmth and Comfort for Outerwear
Fleece is a great choice for hoodies, jackets, and sweatshirts, especially for teams who need extra warmth in cooler settings. Made from synthetic fibers like polyester, fleece is soft, insulating, and lightweight.
Pros of Fleece:
- Warm without being too heavy.
- Quick-drying and durable.
- Comfortable for casual apparel.
Cons of Fleece:
- Too warm for hot climates or active indoor work.
- Can pill over time with heavy use.
- Doesn’t always project a “professional” look compared to polos or uniforms.
For businesses that want to offer employees or clients cozy branded gear—like hoodies for casual Fridays or jackets for outdoor events—fleece is an excellent option.
How Material Affects Print Quality
The type of fabric you choose also plays a big role in how your design looks and lasts.
- Screen Printing: Works best on cotton or cotton blends for crisp, vibrant designs.
- Embroidery: Great for polos, jackets, and thicker fabrics; durable but can feel bulky on lightweight shirts.
- Direct-to-Film (DTF): Versatile option that works well on cotton, polyester, and blends, making it a great all-around choice.
Choosing the right material ensures your print method enhances the design rather than limits it.
Cost Considerations
Material choice also affects cost. Cotton is generally affordable, while performance fabrics and fleece can be pricier. Blends usually fall in the middle, offering good value for businesses looking to balance budget with quality.
It’s also important to think long-term: a durable polyester polo may cost more upfront than a cotton tee but could save money over time if it lasts longer.
Picking the Right Fit for Your Business
Ultimately, the best fabric depends on your goals. If comfort is your priority, cotton might be the way to go. For durability and performance, polyester is hard to beat. Blends provide flexibility for many businesses, while fleece adds a cozy option for outerwear.
At Company Apparel, we guide our clients through these choices, helping them find the fabric that suits their brand, their employees, and their budget. The right material ensures your custom apparel not only looks great but also feels and performs exactly how you need it to.
