How to Choose the Best T-Shirt Material for Custom T-Shirts: Cotton, Polyester, Blends & More

The fabric you choose for your custom t-shirts determines whether people wear them once or make them a regular part of their wardrobe. After helping millions of groups find the right shirts, we’ve learned that fabric choice is the decision that trips people up most often. A shirt that’s too thin feels cheap. A shirt that’s too heavy becomes uncomfortable in summer. The wrong blend can make screen printing look dull or cause the design to crack after a few washes.
This guide breaks down cotton, polyester, and blended fabrics with real manufacturer specifications, head-to-head comparisons, and recommendations based on what we’ve seen work for thousands of groups. The ASI 2023 Ad Impressions Study, which surveyed nearly 25,000 consumers, found that 85% of recipients remember the advertiser who gave them branded apparel. That only happens if the shirt is comfortable enough to actually wear. We’ll help you find the fabric that makes that happen.
In This Article
- 100% Cotton T-Shirts: The Classic Choice
- Polyester and Performance Shirts
- Blends and Tri-Blend Tees
- Fabric Comparison Table: Cotton vs. Polyester vs. Blends
- Fabric Weight Guide: Heavyweight vs. Lightweight Tees
- Matching Material to Your Use Case
- How Printing Methods Work with Different Fabrics
- Fabric Care and Sustainability Considerations
- Frequently Asked Questions
Key Takeaways
- Cotton for comfort, polyester for activity: 100% cotton breathes best and produces the most vibrant prints, while polyester wicks moisture and resists shrinking. Blends give you both.
- Thread count matters more than you think: A 40-singles tri-blend (like the Bella + Canvas 3413) feels dramatically softer than a 20-singles cotton tee, often for just a dollar or two more per shirt.
- Match weight to use case: Lightweight (3.5-4.5 oz.) for retail-quality softness, midweight (4.5-5.5 oz.) for everyday versatility, heavyweight (5.5-6.1+ oz.) for durability and structured screen printing.
100% Cotton T-Shirts: The Classic Choice
Cotton is the most popular fabric for custom t-shirts, and for good reason: it breathes naturally, softens with every wash, and produces the most vibrant colors when screen printed. The fibers absorb ink rather than sitting on top, which means designs look richer and last longer. We carry cotton shirts ranging from budget-friendly options for large promotional orders to premium ringspun styles that rival anything you’d find in a retail store.
The manufacturing process makes a significant difference in how the finished shirt feels. Understanding these differences helps you choose the right cotton for your specific needs.
Types of Cotton Construction
Carded open-end cotton is the most affordable construction method. The fibers are loosely aligned, creating a slightly rougher texture that some people describe as “breaking in over time.” The Gildan Heavy Cotton (G5000) at 5.3 oz., 100% cotton with 20-singles yarn uses this method. These shirts are durable, hold up well to repeated washing, and work great for large group orders where per-shirt cost matters.
Ringspun cotton goes through an additional spinning process that aligns and twists the fibers into a tighter, finer yarn. The result is noticeably smoother and softer right out of the package. The Gildan Ultra Cotton (G2000) at 6.0 oz., 100% preshrunk ringspun cotton uses this construction, and the difference is apparent the moment you touch both shirts side by side.
Combed and ringspun cotton is the premium tier. Short fibers and impurities are combed out before spinning, producing the softest, most uniform fabric available. The Bella + Canvas 3001 uses Airlume combed and ringspun cotton with a 30-singles thread count, which is why it has that retail-quality feel that makes people reach for it over their other t-shirts.
- Best for: Everyday wear, family reunions, casual groups, screen-printed designs where color vibrancy matters
- Pro tip: If softness is a priority, filter by “ringspun” or “combed ringspun” on our product pages. The price difference is often just a dollar or two per shirt, but the hand feel is dramatically better.
- Watch out for: Cotton can shrink 3-5% in length and width after the first few washes if not pre-shrunk. Most of our cotton shirts are pre-shrunk during manufacturing, but check the product details to be sure.
- Print compatibility: Cotton is the ideal surface for screen printing and digital printing (DTG), producing the most vibrant colors and sharpest details.
Customer Story
“Celebrating Marty’s 50th birthday at Lake Keowee in Seneca, South Carolina with 40 of our closest family members and friends. These t-shirts were a HUGE hit with everyone! The high-quality, lightweight material was perfect for a hot day at the lake. We were comfortable all day and will wear our shirts for years to come.”
Featured Products from This Story

Sport-Tek Competitor Performance Shirt
- 100% polyester interlock with PosiCharge technology
- 3.8 oz. lightweight, moisture-wicking fabric
- Sizes XS-4XL, removable tag for comfort

Sport-Tek Women’s Competitor Performance Shirt
- 100% polyester interlock with PosiCharge technology
- 3.8 oz. lightweight, contoured feminine fit
- Sizes XS-4XL, set-in sleeves for comfortable range of motion
Design Inspiration
Polyester and Performance Shirts
When comfort during physical activity is the priority, polyester outperforms cotton in almost every way. The synthetic fibers wick moisture away from the body, dry quickly, and resist wrinkles, shrinking, and fading. We carry polyester performance shirts from brands like Sport-Tek, Hanes Sport, and Nike that are engineered specifically for groups that need to stay comfortable while active.
The ASI 2023 Ad Impressions Study found that performance wear is among the most influential promotional products for consumers ages 25-34, the largest segment of the U.S. workforce. A branded performance shirt that someone actually wears to the gym or on their morning run generates thousands of impressions over its lifetime. The cost per impression for a quality performance shirt works out to less than one cent.
Key Polyester Technologies
PosiCharge technology (Sport-Tek) locks in color so logos and designs stay vibrant wash after wash, while also preventing the fabric from becoming see-through or “pilling” over time. Our Sport-Tek Competitor Performance Shirt (3.8 oz., 100% polyester interlock) uses this technology and is one of our most popular choices for athletic events, charity runs, and company fitness challenges.
Cool Dri technology (Hanes Sport) combines moisture-wicking performance with UPF 50 sun protection, blocking 98% of UVA and UVB rays. The Hanes Sport Cool Dri Performance Shirt (4.0 oz., 100% polyester) is built for outdoor crews, landscaping teams, summer camps, and any group that spends extended time in the sun.
- Best for: Athletic events, outdoor work crews, gym and fitness groups, summer camps, charity runs, any situation involving sweat
- Pro tip: Polyester holds its shape through hundreds of washes with virtually zero shrinkage. For employee uniforms that need to look consistent month after month, polyester or polyester-blend fabrics are the practical choice.
- Watch out for: 100% polyester can feel clingy in non-active settings and doesn’t breathe as well as cotton when you’re not moving. It also requires specific printing methods. Screen printing works, but DTG (direct-to-garment) printing performs best on cotton-rich fabrics.
- Sustainability note: Some of our polyester shirts incorporate recycled materials. In our 2026 Swag Trends Survey, 19% of buyers ranked sustainability as their top product feature, so eco-friendly polyester options are worth considering if your group cares about environmental impact.
Customer Story
“We all work at Walt Disney World and participate in the Canoe Race Of the World every year and we finally got team shirts! We love the bright color and the soft material. Our experience with CustomInk was amazing! Everyone we worked with was very helpful and friendly! We will definitely be ordering again!”
Featured Products from This Story

Sport-Tek RacerMesh Performance Shirt
- 100% polyester RacerMesh with PosiCharge
- 3.2 oz. ultra-lightweight, maximum breathability
- Open-hole mesh construction for airflow

Sport-Tek Women’s RacerMesh V-Neck
- 100% polyester RacerMesh with PosiCharge
- 3.2 oz. ultra-lightweight, contoured fit
- V-neck styling, self-fabric neck tape
Design Inspiration
Blends and Tri-Blend Tees: The Best of Both Worlds
Blended fabrics combine two or three fiber types to deliver the benefits of each while minimizing the drawbacks. Over the past decade, blends have become the default choice for company swag, retail merch, and premium event shirts because they offer that sought-after combination of softness, durability, and a modern fit.
Our 2026 Swag Trends Survey found that 25% of respondents flagged “standard unisex cotton t-shirts” as the swag item becoming most overdone. The era of the basic tee is fading. People still love t-shirts (30% said they’d pick a tee if they could only buy one piece of swag), but fabric quality and fit matter more than ever. Upgrading to a tri-blend or CVC blend is one of the simplest ways to make your shirts stand out.
50/50 Cotton-Polyester Blends
The original blended fabric, 50/50 cotton-poly combines cotton’s softness and breathability with polyester’s durability and wrinkle resistance. The Gildan DryBlend (G8000) is a workhorse option at 5.5 oz., 50/50 cotton/polyester. It features moisture-wicking properties that keep the wearer drier than pure cotton while the cotton content ensures it still feels comfortable against the skin.
- Best for: Team uniforms, work shirts, organizations that want a step up from basic cotton without a significant price increase
- Pro tip: 50/50 blends shrink less than 100% cotton and hold their shape better over time. For employee uniforms that get washed weekly, this consistency matters.
CVC (Chief Value Cotton) Blends
CVC blends contain a higher percentage of cotton (typically 60/40 cotton/polyester) while incorporating enough polyester for improved color retention and reduced shrinkage. The Next Level CVC Crew (6210) at 4.3 oz., 60/40 combed ringspun cotton/polyester, 32 singles is a customer favorite that feels remarkably close to a tri-blend but at a lower price point. The combed ringspun cotton gives it a smooth, soft feel that’s noticeably better than standard cotton.
- Best for: Brand merch, event tees where softness matters, groups that want a premium feel at mid-range pricing
- Pro tip: CVC blends produce a subtle heathered texture in most colors, giving designs a modern, retail-inspired look that’s popular for trendy event shirts.
Tri-Blend Tees (Cotton/Polyester/Rayon)
Tri-blend fabrics combine three fibers, typically polyester, cotton, and rayon, to create one of the softest t-shirt materials available. The rayon component adds drape and breathability, the polyester provides structure and durability, and the cotton delivers that natural, comfortable feel. The result is a shirt with a slightly vintage, broken-in quality right out of the box.
The Bella + Canvas Tri-Blend T-shirt (3413) is the industry benchmark for tri-blend quality. At 3.8 oz., 50/25/25 polyester/Airlume combed and ringspun cotton/rayon, with 40 singles thread count, it’s the industry’s first 40-singles triblend. That finer thread count produces an exceptionally smooth, lightweight fabric that drapes beautifully. It comes in over 50 colors and features side-seam construction for a modern retail fit.
- Best for: Retail merch, boutique apparel, corporate gifts where you want recipients to actually wear the shirt, events where you want to make an impression
- Pro tip: Tri-blends are lightweight, so heavy ink coverage can weigh down the fabric. For the softest result, consider water-based screen printing or DTG printing with a minimal underbase.
- Watch out for: The heathered texture of most tri-blend colors means designs may show slight color variation. This works in your favor for vintage-style prints, but keep it in mind if you need perfectly opaque logos.
Customer Story
“We have been using Custom Ink for the last few years for our family reunion shirts and we love them!! This picture shows all but two of the family members attending our favorite summer camp, sporting our super soft olive green T’s with the little ones in black.”
Featured Products from This Story

Bella + Canvas Tri-Blend T-shirt
- 3.8 oz., 50/25/25 polyester/Airlume combed and ringspun cotton/rayon, 40 singles
- Pre-shrunk, side-seamed retail fit
- Unisex sizing XS-4XL, 50+ colors

Rabbit Skins Jersey Baby Bodysuit
- 5.0 oz., 100% combed ringspun cotton
- Reinforced three-snap closure
- Sizes NB-24 months for family matching

Rabbit Skins Toddler Jersey T-shirt
- 5.5 oz., 100% combed ringspun cotton jersey
- Ribbed crew neck, double-needle hem
- Sizes 2T-5/6T, tear-away label
Design Inspiration
Fabric Comparison Table: Cotton vs. Polyester vs. Blends
This table compares the four major fabric categories across the factors that matter most when ordering custom t-shirts. We’ve included specific product examples with real manufacturer specifications so you can see exactly what you’re getting.
| Property | 100% Cotton | 100% Polyester | 50/50 Blend | Tri-Blend |
|---|---|---|---|---|
| Example Product | Gildan Ultra Cotton (G2000) | Sport-Tek Competitor (ST350) | Gildan DryBlend (G8000) | Bella + Canvas 3413 |
| Fabric Weight | 6.0 oz. | 3.8 oz. | 5.5 oz. | 3.8 oz. |
| Material | 100% preshrunk ringspun cotton | 100% polyester interlock with PosiCharge | 50/50 cotton/polyester | 50/25/25 poly/cotton/rayon, 40 singles |
| Softness | Good (ringspun) to basic (open-end) | Smooth, silky | Moderate | Excellent, broken-in feel |
| Breathability | Excellent | Good (wicks moisture) | Good | Very good |
| Shrinkage | Up to 5% (pre-shrunk reduces this) | Virtually none | Minimal (1-2%) | Minimal (pre-shrunk) |
| Wrinkle Resistance | Low | High | Moderate | Moderate to high |
| Color Vibrancy (Print) | Excellent | Good (sublimation preferred) | Good | Good (heathered effect) |
| Durability | Good | Excellent | Very good | Very good |
| Best Printing Method | Screen print, DTG | Screen print, sublimation | Screen print | Screen print, DTG (light ink) |
| Price Range | $ to $$ | $$ to $$$ | $ | $$ to $$$ |
| Ideal Use Case | Casual events, family groups | Athletic events, outdoor work | Uniforms, budget-friendly groups | Retail merch, premium swag |
Fabric Weight Guide: Heavyweight vs. Lightweight Tees
Fabric weight is measured in ounces per square yard (oz./ydΒ²) and directly affects how a shirt feels, drapes, and performs. We’ve seen enough orders come back with feedback to know that fabric weight is often the factor people overlook first and regret later. A shirt that’s too thin can feel cheap and see-through under heavy ink coverage. A shirt that’s too thick can feel stiff and uncomfortably warm in summer heat.
In our 2026 Swag Trends Survey, 62% of respondents said they plan to try “Heavyweight Tees & Fleece” in 2026, making thick, durable fabrics the number-one trend organizers want to incorporate. Heavyweight has become synonymous with quality in the streetwear-influenced swag market.
Lightweight (3.5-4.5 oz.)
Lightweight tees feel soft, breathable, and modern. They drape closer to the body and have a more fitted, retail-quality silhouette. The Bella + Canvas 3001 (4.2 oz., 100% Airlume combed and ringspun cotton) and the Bella + Canvas 3413 tri-blend (3.8 oz.) both fall in this range.
- Best for: Retail merch, fashion-forward events, warm-weather wear, groups that prioritize softness and fit
- Pro tip: Lightweight shirts look and feel premium, but heavy screen printing (multiple colors, large designs with heavy ink coverage) can weigh down the fabric and create a stiff feel on the print area. Water-based or DTG printing keeps the hand feel soft.
Midweight (4.5-5.5 oz.)
This is the versatile middle ground for most custom t-shirt orders. Midweight shirts offer a balanced combination of durability, comfort, and value. The Gildan Heavy Cotton G5000 (5.3 oz., 100% cotton) and the Gildan Softstyle (4.5 oz., 100% ringspun cotton) both sit in this range and account for a large share of our total t-shirt volume.
- Best for: General-purpose events, group orders, promotional giveaways, school and church groups
- Pro tip: If you’re ordering for a mixed group and aren’t sure what weight to choose, midweight is the safe choice. It works across seasons and use cases without feeling too heavy or too flimsy.
Heavyweight (5.5-6.1+ oz.)
Heavyweight t-shirts have a substantial, structured feel. They hold their shape well, resist see-through issues, and project a sense of quality and durability. The Gildan Ultra Cotton G2000 (6.0 oz., 100% preshrunk ringspun cotton) and the Hanes Beefy-T (6.1 oz., 100% cotton) are classic heavyweight options that have been popular with work crews and organizations for decades.
- Best for: Work uniforms, construction crews, organizations that want a substantial feel, cold-weather layering
- Pro tip: Heavyweight cotton tees are ideal for screen printing. The thicker fabric holds ink beautifully, and heavy designs don’t create a noticeable weight difference the way they would on a lightweight shirt.
Fabric Weight Comparison Table
| Weight Category | Oz. Range | Example Product | Material | Best For |
|---|---|---|---|---|
| Lightweight | 3.5-4.5 oz. | Bella + Canvas 3413 | 50/25/25 tri-blend, 40 singles | Retail merch, premium swag |
| Lightweight | 3.5-4.5 oz. | Gildan Softstyle (G6400) | 4.5 oz., 100% ringspun cotton, 30 singles | Fashion-forward groups, events |
| Midweight | 4.5-5.5 oz. | Gildan Heavy Cotton (G5000) | 5.3 oz., 100% cotton, 20 singles | General orders, budget groups |
| Midweight | 4.5-5.5 oz. | Gildan DryBlend (G8000) | 5.5 oz., 50/50 cotton/poly | Uniforms, active groups |
| Heavyweight | 5.5-6.1+ oz. | Gildan Ultra Cotton (G2000) | 6.0 oz., 100% preshrunk ringspun cotton | Work shirts, structured looks |
| Heavyweight | 5.5-6.1+ oz. | Hanes Beefy-T (5180) | 6.1 oz., 100% cotton | Durability, heavy screen printing |
Customer Story
“A great day at the lake with our wonderful family. After all the ‘real’ photos were taken, we let loose with silly faces. We love the shirts: they fit great, the printing is perfect and they feel soft and wonderful. Thanks for making our gathering a success!”
Featured Products from This Story

Hanes Women’s Perfect-T V-Neck
- 4.5 oz., 100% ringspun cotton
- Contoured feminine fit with V-neck
- Sizes S-3XL, tag-free for comfort

Hanes EcoSmart 50/50 T-shirt
- 5.2 oz., 50/50 cotton/polyester blend
- Made with up to 5% recycled polyester
- Sizes S-6XL, tag-free, lay-flat collar
Matching Material to Your Use Case
The “best” fabric is always the one that fits the situation. A premium tri-blend is wasted on disposable event giveaways, and a basic cotton tee won’t impress your top clients at a corporate retreat. Here’s how we’d guide you based on common use cases.
Corporate Swag and Employee Gifts
For company swag, fabric quality directly impacts whether the shirt ends up in someone’s regular rotation or at the back of a drawer. In our 2026 Swag Trends Survey, 47.6% of respondents said seeing swag end up in the trash or donation pile motivates them to invest in better quality next time. And 91% of respondents believe their team feels more valued when receiving a recognized retail brand compared to a generic private label item. Tri-blends and CVC blends from brands like Bella + Canvas or Next Level are the smart move.
- Recommended fabric: Tri-blend (Bella + Canvas 3413) or CVC blend (Next Level 6210)
- Pro tip: Use our group order feature to let each employee choose their own size and preferred fit. You can set up a single design and let everyone order individually.
Athletic Events and Charity Runs
Moisture-wicking polyester is the clear choice for any event where participants will be sweating. Comfort is critical because these shirts serve as both the uniform and the souvenir. Performance fabrics with PosiCharge or Cool Dri technology keep colors locked in even after heavy use and repeated washing.
- Recommended fabric: 100% polyester (Sport-Tek Competitor ST350 or Sport-Tek RacerMesh) or polyester blend with moisture-wicking
- Pro tip: Order samples before committing to a large order. We’re happy to send samples so you can feel the fabric and test the fit before placing your full order.
Family Reunions and Casual Groups
For large family groups that include everyone from babies to grandparents, comfort and value are the priority. A midweight cotton tee in the 5.0-5.5 oz. range hits the sweet spot: soft enough to wear all day, durable enough to last through years of reunion photos, and affordable enough to order for 40+ people without stretching the budget.
- Recommended fabric: Gildan Heavy Cotton (G5000) for budget orders, Gildan Softstyle (G6400) if softness matters more
- Pro tip: Many of our products have no minimums, so you can add a few onesies and toddler sizes to match the rest of the group without meeting a large minimum order.
Use Case Quick-Reference Table
| Use Case | Recommended Fabric | Weight | Why |
|---|---|---|---|
| Corporate swag / employee gifts | Tri-blend or CVC blend | 3.8-4.5 oz. | Premium feel, retail-quality softness |
| Athletic events / charity runs | 100% polyester | 3.2-4.0 oz. | Moisture-wicking, quick-dry |
| Family reunions / casual groups | 100% cotton (midweight) | 5.0-5.5 oz. | Comfortable, affordable at scale |
| Work uniforms / crews | 50/50 blend or heavyweight cotton | 5.5-6.1 oz. | Durable, holds shape, easy care |
| Retail merch / brand store | Tri-blend or combed ringspun cotton | 3.8-4.5 oz. | Soft hand feel, vintage drape |
| Trade show giveaways | Midweight cotton | 5.0-5.3 oz. | Value-priced, good print surface |
| School / youth groups | Cotton or 50/50 blend | 5.0-5.5 oz. | Durable, wide size range, budget-friendly |
How Printing Methods Work with Different Fabrics
The fabric you choose affects which printing methods will produce the best results. We want to make sure your design looks as good in person as it does in our Design Lab. Here’s how the major decoration methods pair with different fabric types.
Screen printing works well on virtually all fabric types but performs best on 100% cotton and cotton-rich blends. The ink sits on top of the fabric, producing vibrant, opaque colors. Heavier cotton shirts (5.3-6.1 oz.) give screen-printed designs a clean, professional finish because the fabric provides a stable, smooth surface.
Digital printing (DTG and DTF) produces photo-quality results and works best on 100% cotton or cotton-rich blends. DTG ink bonds directly with cotton fibers, which is why 100% cotton typically produces the most vibrant digital prints. DTF (direct-to-film) transfers work on a wider range of fabrics including polyester and are an excellent option when you need photo-realistic prints on performance wear.
Embroidery pairs well with heavier, denser fabrics that can support the weight of the thread without puckering. Midweight to heavyweight cotton tees (5.0+ oz.) and structured polo shirts are ideal candidates. In our 2026 Swag Trends Survey, over 53% of buyers said they’re “very” or “extremely” interested in premium decoration methods like embroidery, leather patches, or laser engraving. Embroidery projects a level of quality that screen printing alone doesn’t match.
Printing Method Compatibility Table
| Printing Method | 100% Cotton | 100% Polyester | 50/50 Blend | Tri-Blend |
|---|---|---|---|---|
| Screen Printing | Excellent | Good (requires special ink for darks) | Very Good | Good (light ink recommended) |
| DTG (Direct-to-Garment) | Excellent | Not ideal | Good | Good |
| DTF (Direct-to-Film) | Very Good | Very Good | Very Good | Very Good |
| Sublimation | Not recommended | Excellent (white/light only) | Limited | Limited |
| Embroidery | Excellent (5.0+ oz.) | Good (with backing) | Very Good | Fair (small designs only) |
Customer Story
“We had another great experience working with Custom Ink for our dragon boat team t-shirts. Easy to use group order process, shipped on time, great quality product, and excellent customer service.”
Featured Products from This Story

Gildan Softstyle Jersey T-shirt
- 4.5 oz., 100% ringspun cotton, 30 singles
- Semi-fitted contoured silhouette
- Sizes S-5XL, 57+ color options

Gildan Softstyle Long Sleeve Jersey
- 4.5 oz., 100% ringspun cotton, 30 singles
- Matching long-sleeve for cooler weather
- Sizes S-3XL, same soft hand feel
Fabric Care and Sustainability Considerations
How you care for your custom t-shirts directly affects how long they last and how good they continue to look. Sharing care tips with your group can extend the life of their shirts significantly.
Care Tips by Fabric Type
Cotton: Wash in cold water to minimize shrinkage and preserve print vibrancy. Tumble dry on low or air dry. Cotton can shrink up to 5% if washed in hot water and dried on high heat, even when labeled as “pre-shrunk.” Turn shirts inside-out before washing to protect screen-printed designs from friction.
Polyester: Machine wash cold or warm. Polyester resists shrinking and holds its shape regardless of wash temperature, but cold water helps maintain color brightness longer. Avoid fabric softener, which can coat the fibers and reduce moisture-wicking performance. Tumble dry on low; polyester dries quickly and doesn’t need extended dryer time.
Blends and tri-blends: Wash cold, tumble dry low. These fabrics are generally low-maintenance. The polyester content helps resist shrinkage, while the cotton component benefits from gentle wash settings. Turn inside-out to protect prints.
Sustainability
Sustainability is increasingly important to the groups we work with. In our 2026 Swag Trends Survey, 19% of buyers ranked sustainability as their top product feature consideration. Several of the shirt brands we carry incorporate eco-friendly practices into their manufacturing.
- Bella + Canvas uses sustainable manufacturing processes including BLUESIGN-certified dyes, efficient dye houses adhering to California EPA regulations for wastewater treatment, and cutting facilities powered by partial solar energy with comprehensive recycling programs.
- Gildan uses OEKO-TEX certified low-impact dyes and is a member of the U.S. Cotton Trust Protocol, ensuring responsible cotton sourcing.
- Hanes EcoSmart products incorporate up to 5% recycled polyester made from plastic bottles.
- The most sustainable choice: The most sustainable t-shirt is one that gets worn regularly instead of tossed in a drawer. Investing in higher-quality fabric that people actually want to wear is often more impactful than choosing a specific eco-labeled product that ends up unused.
Design Inspiration
How to Order Your Custom T-Shirts
- Pick your product. Browse our full custom t-shirt catalog and filter by fabric type, weight, brand, or price. Each product page includes detailed specs, available colors, and sizing information.
- Design it. Open the Design Lab to upload your logo, choose from our template library, or use our clipart to build something from scratch. The Design Lab shows you exactly how your design will look on the actual product before you order.
- Get help if you need it. Our design experts can help you refine your artwork, suggest the best print method for your chosen fabric, and recommend products based on your use case. There’s no extra cost for design help.
- Set up group ordering (optional). If your group members need different sizes, our group order feature lets everyone select their own size, color preference, and shipping address. You can even let each person pay separately.
- Place your order. We offer free standard shipping on all orders, with delivery in about two weeks. Need it faster? Rush options are available for an additional charge.
Ready to get started? Choose the fabric that fits your group, open the Design Lab, and start creating.
Frequently Asked Questions
Q: What is the softest t-shirt material for custom printing?
Tri-blend fabrics (a mix of polyester, cotton, and rayon) are generally the softest option we carry. The Bella + Canvas Tri-Blend T-shirt (3413) at 3.8 oz. with a 40-singles thread count is one of our most popular choices for groups that prioritize softness. CVC blends like the Next Level 6210 are another excellent option at a slightly lower price point. If you prefer 100% cotton, look for “combed and ringspun” in the product description, which indicates a finer, smoother yarn.
Q: What’s the difference between 100% cotton and polyester t-shirts?
Cotton is a natural fiber that breathes well, softens with washing, and produces the most vibrant colors when screen printed or DTG printed. It can shrink and wrinkle. Polyester is a synthetic fiber that resists shrinking, wrinkles, and fading while wicking moisture away from the body. Polyester is better for active use and holds its shape wash after wash. The tradeoff: cotton breathes better when you’re not moving, while polyester performs better during physical activity. Blends combine the strengths of both.
Q: What fabric weight should I choose for custom t-shirts?
For general-purpose orders, a midweight shirt in the 4.5-5.5 oz. range works for most situations. Lightweight tees (3.5-4.5 oz.) feel softer and more modern but may not support heavy screen printing as well. Heavyweight tees (5.5-6.1+ oz.) are ideal for work uniforms, cold-weather layering, and designs with heavy ink coverage. When in doubt, contact our team for a recommendation based on your specific needs.
Q: Can I order just one custom t-shirt, or are there minimum requirements?
Many of our products have low or no minimums, so you can order as few as one shirt. Just check the product details or filter by “no minimum” when browsing. Per-shirt pricing decreases as your quantity goes up, so you’ll see the best value on larger orders.
Q: Are bulk discounts available for custom t-shirts?
Yes. We offer volume pricing on all products. The more you order, the lower your per-unit cost. You can see the price breaks right on the product page as you adjust the quantity. For very large orders, you can also explore our bulk ordering options for additional savings.
Q: How far in advance should I order custom t-shirts?
Orders typically arrive within two weeks with our free standard shipping. If you need your shirts sooner, rush options are available for an additional charge. We recommend ordering at least three weeks before your event to allow time for design revisions and any unexpected delays.
Q: Can members of my group each choose their own t-shirt size?
Absolutely. Our group order feature lets each person in your group select their own size, choose their preferred color (if applicable), enter their own shipping address, and even pay separately. You can also collect all sizes yourself and pay for the entire order if you prefer to ship everything to one location.
Q: Can I get help choosing the right t-shirt material for my group?
Yes. Our design experts know our product catalog inside and out and can recommend the best fabric type, weight, and brand for your specific use case. You can also reach us by phone, chat, or email. We’re available 7 days a week.
Q: Which t-shirt material is best for screen printing?
100% cotton is the top choice for screen printing because the fibers absorb ink well and produce vibrant, long-lasting prints. Midweight to heavyweight cotton tees (5.0-6.1 oz.) provide the best surface. 50/50 blends also perform very well. Tri-blends and polyester can be screen printed but may require adjusted techniques for optimal results. Our team can advise on the best print method for any fabric.
Q: Do tri-blend t-shirts shrink?
Tri-blend tees experience minimal shrinkage because the polyester content (typically 50%) stabilizes the fabric. Most tri-blends from brands like Bella + Canvas are also pre-shrunk during manufacturing. Washing in cold water and tumble drying on low will help maintain the original fit. You’ll see far less shrinkage with a tri-blend compared to a 100% cotton shirt.
Q: What does “singles” mean in t-shirt fabric specifications?
“Singles” refers to the thickness of the yarn used in the fabric. The higher the number, the finer and thinner the thread. A 20-singles yarn (like the Gildan Heavy Cotton G5000) produces a standard, sturdy fabric. A 30-singles yarn (Gildan Softstyle) is finer and softer. A 40-singles yarn (Bella + Canvas 3413) is extremely fine, producing an ultra-smooth, lightweight fabric with a premium hand feel. If softness is your priority, look for higher singles counts.















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