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How to Choose a T-Shirt: Fabric Guide
Choosing the right T-shirt fabric isn’t just about comfort — it’s about performance, durability, branding impact, cost per unit, and how much your team members will wear them. Whether you’re a small business owner ordering a corporate tee, a school director outfitting a club, an event organizer planning merch, or just someone who wants the perfect custom shirt, the fabric you choose matters more than you might think.
This full guide goes deeper than the basics to help you understand fabric types, how they feel and wear over time, why they matter for printing and apparel branding, and how to make the best choice for every occasion.
1. Why Fabric Choice is Critical for Custom Shirts
Every shirt starts with a fabric — and not all fabrics are created equal.
- Comfort affects how often your shirts get worn. If your team gets sweaty and uncomfortable, they’re less likely to wear your shirts beyond the day you distribute them.
- Fabric impacts print quality. Some materials take ink better, hold embroidery better, or make colors pop more vibrantly.
- Durability matters for uniforms and merchandise. A cheap shirt might look nice at first, but will it survive washing?
- Performance fabrics do work that ordinary cotton can’t. For athletic events or outdoor jobs, advanced fabrics can make a big difference in comfort and wearability.
This guide will help you pick the fabric that best fits your purpose, budget, and branding goals.
2. T-Shirt Fabric Types — Explained (With Pros & Cons)
Let’s break down the most common fabrics you’ll see on custom shirt sites — and what makes each one great (or not) for your specific use.
A. 100% Cotton — The Classic Comfort King
Best for: Everyday wear, casual apparel, giveaways, retail merchandise.
Cotton is the most widely used natural fiber for T-shirts. It’s soft, breathable, and feels great next to skin — perfect when comfort is your top priority.
| PROS | CONS |
| ✔ Extremely comfortable and breathable. ✔ Great surface for printing methods like screen ✔ printing or DTG (direct to garment) printing. ✔ Natural fiber — biodegradable and gentle on skin. ✔ Works well in everyday, casual shirts. | ✘ Can shrink or wrinkle if not pre-shrunk or washed carefully. ✘ Absorbs moisture instead of wicking it away, which isn’t ideal for heavy activity. |
Example from Broken Arrow:
- Bella+Canvas 3001 – 4.2oz Airlume Cotton T-Shirt — a high-quality cotton tee that feels soft and looks sharp.
B. Polyester — The Performance Powerhouse
Best for: Sports teams, outdoor events, athletic uniforms.
Polyester is a synthetic fiber that excels in moisture management and durability. It dries quickly, resists wrinkles, and holds its shape even after repeated washes.
Think of polyester tees when your audience will be active or outdoors a lot — such as golf outings, marathons, team practices, or company retreats.
| PROS | CONS |
| ✔ Moisture-wicking — perfect for hot weather or physical activity. ✔ Less likely to shrink or wrinkle. ✔ Great for “performance” or technical shirts. | ✘ Can sometimes feel less soft than cotton. ✘ Less breathable without moisture-wicking treatments. |
Example from Broken Arrow:
- Sport Tek T473 – Dry Zone Short Sleeve Tee — a high-quality 100 percent polyester T-shirt that moves with you thanks to raglan sleeves and roomy cut.
C. Cotton-Polyester Blends — The Best of Both Worlds
Best for: All-purpose shirts, uniforms, extended retail use.
Blends combine cotton’s comfort with polyester’s resilience. For example, a 50/50 cotton/poly blend gives you a shirt that’s still soft, more shrink-resistant, more durable, and a slightly easier care routine.
Blends are among the most popular choices for businesses because they balance cost, comfort, and performance.
| PROS | CONS |
| ✔ Softer than 100% polyester. ✔ More durable and less wrinkly than pure cotton. ✔ Great value for branded shirts or staff uniforms. | ✘ Breathability depends on the ratio — more polyester means less airflow. |
Example from Broken Arrow:
- American Apparel 2004CVC — a high-quality cotton/poly blend high V-neck tee with a soft feel and a classic fit.
D. Tri-Blend — Soft Meets Stylish
Best for: Retail merch, boutique apparel, soft-feel promotional shirts.
Tri-blend fabrics mix cotton + polyester + rayon to create an ultra-soft, slightly stretchy shirt that drapes well and looks stylish.
Many customers choose tri-blends for retail merchandise because these shirts feel premium without huge cost.
| PROS | CONS |
| ✔ Super-soft “lived-in” feel. ✔ Great for lifestyle wear and fashion-oriented projects. ✔ Less prone to wrinkles and comfy in a wide range of climates. | ✘ Slightly higher cost than basic cotton or blended tees. |
Example from Broken Arrow:
- Royal Apparel 20051 – A high-quality ultra soft triblend t-shirt that features a flattering drape and comfort fit.
3. How Fabric Affects Printing & Embroidery
When you’re putting your logo, mascot, or slogan on a shirt, the fabric makes a big difference in the final result.
Works beautifully on smoother,
cotton-rich fabrics.
Photographic prints benefit from tight-knit fabrics like ring-spun cotton.
Denser fabrics hold stitches better and look more professional.
That means your fabric choice should match your decoration method. If you want premium embroidery on staff polos, choose a fabric with enough structure to keep stitching crisp.
4. Choosing the Right Fabric for Your Project
Here’s how you can match fabrics with your specific needs:
Promotional Giveaways
- Go with: Cotton or cotton-polyester blends.
- Why: They feel comfortable, are budget-friendly, and still look good with your printed design.
Athletic Events or Team Wear
- Go with: Performance polyester or moisture-wicking blends.
- Why: They keep participants cool and dry.
Retail Merchandise
- Go with: Tri-blend or high-quality ring-spun cotton.
- Why: The perceived quality is higher — so you can charge more and keep returns low.
Company Uniforms
- Go with: Cotton-polyester blends or polos with a bit more structure.
- Why: They’re durable, comfortable, and look professional even after repeated washes.
5. Why Choose Broken Arrow T-Shirt Printing and Embroidery for your custom shirts?
When you order custom shirts from Broken Arrow T‑Shirt Printing and Embroidery, you’re getting more than just logos on shirts — you’re partnering with a company that understands quality fabrics, expert printing, and customer needs inside and out:
Expert Customer Service
Broken Arrow’s team is U.S.-based and available weekdays with real people — not chat bots — to help you through every step from design to delivery.
Free Shipping & Fast Turnaround
Every order ships free within the contiguous U.S., often delivered in as little as 6 business days with faster rush options available.
Free Artwork Assistance
Not sure how your logo should look? Broken Arrow’s in-house art team can help you refine or build your custom design for no extra setup fee when you order 6 or more.
In-House Printing & Embroidery
With a state-of-the-art facility right in Des Moines, Broken Arrow controls the print and embroidery process from start to finish — so quality and deadlines are dependable.
Wholesale Pricing for Everyone
No need to be a large corporation — every customer gets great pricing on name brands like Nike, Gildan, Champion, Bella+Canvas, and more.
6. Top Broken Arrow Products You Can Order Today
Here are some of the most popular custom shirt options available through their easy online design portal:
Custom T-Shirts & Tees
- Canvas 3001 – 4.2oz Airlume Cotton T-Shirt — super soft and perfect for retail merch, staff tees, or event giveaways.
- Gildan 5000 – 5oz 100% Cotton Tee — budget-friendly and classic.
- District Made DT1350 – 4.5oz Perfect Triblend V-Neck Tee — soft and modern feel.
Polos & Professional Wear
- Custom polos ideal for corporate uniforms and events (designable with logo front and back).
Hats, Hoodies, & More
- From hoodies to bags and beyond, Broken Arrow offers customization on a full range of apparel and accessories.
Start designing any of these via the Broken Arrow custom shirt builder: https://www.brokenarrowwear.com/tshirtprinting/
7. External Fabric Guide for Further Learning
To dive deeper into fabrics — including weave types, fabric weights, and how materials impact garment performance — check out this fashion-oriented fabric guide:
T-shirt Fabric Guide: Choosing the Best Material — a detailed look at fabric choices and what they mean for comfort and durability from Next Level Apparel: Good, Better, Best: T-Shirt Fabrics for any Price Point
8. Final Fabric Selection Checklist
Before you finalize your order, here’s a quick checklist to ensure you choose the best fabric:
✔ What will the shirts be used for?
✔ Will wearers be active or sedentary?
✔ Do you want premium feel or budget simplicity?
✔ What printing or decoration method will you use?
✔ How many shirts are you ordering?
✔ Do you need delivery by a specific date?
Once you’ve answered these, you’ll be ready to design, order, and deliver the perfect custom shirts.
Fabric Matters!
Choosing the best T-shirt fabric can make or break your custom apparel project. Understanding cotton, polyester, blends, and tri-blends — and matching them to your audience and usage — means you get shirts people want to wear. With professional guidance, free design help, fast shipping, and expert printing services from Broken Arrow, you’ll be ready to take your brand to the next level with custom apparel that feels as good as it looks.
[…] Broken Arrow T-Shirt Selection Guide Part 2 Are you choosing the right T-shirt for your needs? What are the differences between performance T-shirts and other T-shirts? Should you choose a tri-blend T-shirt, a 100 percent cotton T-shirt, or a cotton-poly blend? Broken Arrow T-Shirt Printing and Embroidery has the answers! What is a Performance T-Shirt? + Read More […]