A Comprehensive Guide to Cotton, Polyester, and Blended Fabrics

Alex Galindo

Published May 29, 20239 mins read

While starting a clothing brand may rely heavily on your designs and branding strategies, at the end of the day, it all boils down to fabric choice and quality. Thus, in this article, we’ll explore the three most popular fabric types that custom apparel makers rely on—cotton, polyester, and blended fabrics. By the end, you’ll know exactly what fabric to use for your custom apparel and why.

Defining Cotton, Polyester, and Blends

First things first, let’s get to know the basics about each of these three fabric types.

Cotton

As you may have known already, cotton is the most popular natural fabric used in the apparel industry. It’s an incredibly versatile material that comes with great breathability, softness on the skin, and optimum durability. Cotton fibers are known to be extremely absorbent and can both hold as much as 27 times their own weight in water. Thus, it’s no wonder why cotton fabric is mostly used in hot and humid regions.

This fabric is always among the top choices of custom apparel makers due to its easy availability. It’s also an incredibly versatile material that comes in various weights and styles, including jersey knit, flannels, twill, and more.

Polyester

On the polar opposite of cotton is polyester. Polyester is a type of synthetic fabric that is made from petroleum. Nowadays, there are also polyester fabrics made from recycled plastics including water bottles and agricultural waste. They are commonly used in custom apparel because of their immunity to shrinking, wrinkling, and fading over time.

Contrary to popular belief, polyester by itself isn’t really elastic or stretchable. It needs a bit of help from elastane or spandex fibers to be stretchy. Nonetheless, it’s among the most durable fabric choices in the market and its ability to keep moisture away from the skin makes it a great pick for outdoor activities.

Blends

Choosing between the two, plus other fabric types, can be quite difficult. This is exactly why blended fabrics exist.

As you may have guessed, blended fabrics are a combination of different fiber materials, such as cotton and polyester. They are available in many forms and combinations, such as cotton-poly blends, tri-blend fabric, and poly-viscose. Oftentimes, blended fabrics are more affordable than pure materials, but they also possess qualities from both sides.

For example, a cotton-poly blend will have the breathability of cotton and durability of polyester. Therefore, it’s a great choice for those who are looking for an affordable and versatile fabric option to use in their custom apparel.

The Advantages and Disadvantages of Cotton, Polyester, and Blends

Of course, each type of fabric comes with its own pros and cons. Here, we’ll outline the advantages and disadvantages of cotton, polyester, and blended fabrics to help you make a more informed decision.

The Pros and Cons of Cotton Fabric

Let’s start with the most popular one—cotton. Here are just some of the advantages and disadvantages of cotton fabrics.

Highly Breathable

Cotton is always one of the top choices when it comes to comfy, breathable clothing. It absorbs moisture quickly and keeps your body cool, making it perfect for hot summer days. This advantage is also what makes cotton fabrics a great pick for light outdoor activities or casual wear.

Low Retention of Odors

Cotton fibers don’t cling to odors easily, making them ideal for those who are sensitive to smells. This is especially great when you’re wearing clothes for long hours, since odors are less likely to build up.

Soft on the Skin

Cotton is naturally soft and feels comfortable on the skin. It’s perfect for those who have sensitive skin, as well as babies and toddlers. Unlike synthetic fabrics, cotton is much gentler on the skin and is not prone to causing any allergies or skin irritations.

A Sustainable Option

Generally, cotton is the most sustainable choice among the three. Because it is a natural fiber, it can biodegrade and decompose easily. Most of the cotton fabrics used today are also organically grown, meaning they are free from harmful pesticides and chemicals.

Can Easily Shrink and Fade

What makes cotton so special also makes it slightly difficult to maintain. Because of its natural composition, cotton fabrics are prone to shrinking when washed and dried on high heat settings. Moreover, the fabric’s color can easily fade over time due to exposure to direct sunlight.

Nonetheless, there are preshrunk 100% cotton shirts like the Gildan – 5000L women’s t-shirts which are made to maintain their size even after multiple washes.

Prices Fluctuate from Time to Time

Because cotton is sourced from natural materials, its prices are expected to be a bit lower than synthetic fibers. However, this doesn’t stay the same all year round. The prices of cotton fabrics can change due to market forces, such as global demand and supply. Plus, environmental factors that could affect the production of cotton can also cause sudden price increases.

The Pros and Cons of Polyester Fabric

Now, moving on to polyester. Here are some of the pros and cons of using this synthetic fabric.

Widely Available

Because polyester is man-made, it is a lot easier to produce than cotton fabrics. This makes it more widely available than other natural fibers. Furthermore, polyester can also be processed more quickly, allowing manufacturers to create garments much faster.

Durable and Resilient

As mentioned earlier, polyester is known for its durability and resilience. It is much less likely to shrink or fade than cotton fabrics, making it a great choice for long-term clothing items. It does not lose its shape easily, so even after many washes and wears, you can expect your shirt to maintain its original form.

Lightweight and Water-Resistant

Polyester is a light fabric, making it perfect for activewear such as the C2 Sport – 5600. Its ability to repel moisture also makes it great for outdoor activities and sports.

Relatively Inexpensive

Unlike cotton, polyester isn’t susceptible to market changes. This makes its prices more stable throughout the year. It tends to be cheaper than 100% natural fabrics, making it a great option for budget-conscious shoppers.

Not as Breathable as Cotton

One disadvantage of polyester is its lack of breathability. The synthetic fibers don’t absorb moisture as easily, making it somewhat uncomfortable for those who sweat a lot. While it’s a popular choice for activewear, those with more sensitive skin may find it a bit too abrasive and suffocating.

Retains Odor

Another downside of polyester is its tendency to retain odors. It clings easily to sweat and other smells, making it less suitable for those who need to remain odor-free during long hours. It may also require special washing cycles to ensure that odors are removed.

Static-Prone and Prone to Pilling

Because polyester is a synthetic fabric, it is prone to static and pilling. It tends to cling to the body and produce an electric charge, making it uncomfortable to wear in cold weather. Additionally, the fabric’s fibers are prone to pilling, which causes it to form tiny balls that may look unsightly.

Not as Eco-Friendly as Cotton

Of course, another disadvantage of polyester is its lack of eco-friendliness. Unlike cotton, it does not decompose as easily, so it tends to stick around in landfills for a long time if not disposed of properly. It can also release harmful chemicals into the environment during its production.

The Pros and Cons of Fabric Blends

Finally, we have the fabric blends. Here are some of the advantages and disadvantages of using a blend rather than 100% cotton or polyester.

Best of Both Worlds

As mentioned, people often opt for blends because of their ability to combine the best features of both fabrics. For instance, a poly-viscose shirt like the Bella+Canvas – 8882 cropped tee has a flowy drape of viscose with the durability and wrinkle resistance of polyester.

Wide Variety of Combinations Available

There are countless combinations of fabrics available in the market today. You can find blends that combine natural and synthetic fibers for a unique look, or mixtures composed solely of natural fibers. Some of the more popular combinations include rayon-cotton, bamboo-cotton, and cotton-polyester.

More Affordable than Pure Materials

Because some natural fabrics like linen and silk are relatively expensive, blending them with cheaper synthetic materials helps to reduce costs. This makes blends a great choice for those who don’t want to spend too much on fabric.

Could be Less Durable and Resilient than Pure Fabrics

Unfortunately, blends may not be as durable or resilient as fabrics composed of pure materials. For instance, a fabric blend made of more cotton than polyester might not be as wrinkle-resistant or long-lasting as an all-polyester fabric. Also, some blends may shrink in the wash, especially if they contain more natural fibers.

Tends to be Less Comfy than Pure Fabrics

Blends also tend to be less comfortable than fabrics made of pure natural fabrics. Some combinations that use more synthetic fibers may feel harsher and abrasive against the skin. Thus, it’s important to check the fabric content when buying a garment made of blend material.

May Require Special Care

Because different blends are composed of different materials, they may require special care when washing and drying. For instance, fabrics made up of more natural fibers will need to be washed in cool temperatures and hung to dry. Whereas those composed of more synthetic fibers can be tossed into the washing machine without any extra precautionary measures.

How to Care for Cotton, Polyester, and Blended Fabrics

Since we are on the subject of wash and care, let’s take a look at the proper care routine for cotton, polyester, and blended fabrics.

Washing

When it comes to washing, both cotton and polyester would require cold water and mild detergents. Because the former is prone to shrinking and the latter is made with synthetic fibers, it’s important to avoid hot water that can damage the fabric. As for the washing machine settings, it’s best to opt for gentle or delicate cycle when cleaning cotton shirts. Polyester, meanwhile, can be washed with regular cycle and wouldn’t usually require any special precautions.

For blended fabrics, the care instructions will depend on the type of fibers used. It’s best to check the label for specific washing guidelines to prevent any damage. For instance, a shirt made of rayon-cotton blend would require gentle cycle and cool to warm water temperature.

Drying

Cotton shirts should always be hung to dry, as this will help to prevent any further shrinkage. Putting a 100% cotton shirt in the dryer can result in its fibers becoming stiff, especially if it is tumble-dried at high temperatures.

For polyester and blended fabrics, some can be tumble-dried on low heat, but it’s always best to check the care label first. This can help prevent any accidental damage such as discoloration or fading due to excess heat.

Ironing and Steaming

Ironing and steaming are two of the most popular methods used to remove wrinkles and help garments look neat. Cotton can be unwrinkled by just using iron and setting it at a low to moderate temperature. Doing this while the shirt is still damp or slightly humid can further help to achieve a wrinkle-free finish.

Polyester, on the other hand, requires low heat while ironing so as to prevent any burns. Steaming is also a great way to get rid of wrinkles from polyester and blended fabrics, especially those that contain stubborn or delicate fibers like silk, wool, and rayon.