Guide to Cotton, Polyester, and Blended Fabrics

Whether you're new to the print-on-demand industry or have been in it for some time, it's always beneficial to learn or revisit your understanding of cotton and polyester fabrics.

The fabrics you choose are crucial. In fact, the material composition of a garment is perhaps the most significant factor when it comes to selling apparel.

Different fabrics have distinct characteristics. While a garment might look stunning, if the fabric is of poor quality, wears out quickly, or shrinks excessively, it won't attract your customers.

Every clothing retailer needs to know the three main fabric types: cotton, polyester, and blended fabrics. In this blog post, we'll explore each one in detail to help you choose the best options for your store.

What Is a Fiber?

Fibers are the basic building blocks of fabrics. They are thin, thread-like structures that are either natural or synthetic.

Natural fibers, like cotton, wool, and silk, are derived from plants, animals, or minerals. Synthetic fibers, such as polyester and nylon, are man-made through chemical processes. 

The properties of the fiber determine the characteristics of the fabric, including its texture, strength, and durability.

Fibers are classified into two categories:

Natural Fibers

• These are fibers that are directly obtained from natural sources.
• They are biodegradable, renewable, and often hypoallergenic. 
• Natural fibers originate from plants, animals, and minerals. 
• Cotton is the most commonly used plant fiber in fabrics, with flax and burlap also being notable plant fibers.
• Wool is the most prevalent animal fiber, while silk is another well-known animal fiber.
• A mineral fiber example is asbestos.

Synthetic Fibers

• These fibers are created through chemical processes, usually from petrochemicals.
• Synthetic fibers are known for their strength, elasticity, and resistance to wrinkles and shrinkage.
• Synthetic fibers are derived from man-made sources. 
• These fabrics are created using materials like petroleum-based chemicals (petrochemicals), cotton linters left from the ginning process, and wood pulp from lumber production:
• Polyester is a type of petrochemical. Other frequently used petrochemicals include nylon, acrylic, and olefin.
• Rayon, acetate, and triacetate are examples of fibers made from wood pulp.

What Is a Fabric?

Fabric is created by weaving or knitting fibers together. The type of fiber used, the way it is spun into yarn, and the weaving or knitting method all contribute to the final characteristics of the fabric. 

For example, cotton fabric is soft and breathable, making it ideal for clothing. Polyester fabric, on the other hand, is durable and resistant to wrinkles, making it suitable for a wide range of applications.

There are various methods for creating fabric from yarn, but the two primary techniques are:

• Weaving: This involves interlacing two sets of yarns so that they intersect, typically at right angles.
• Knitting: Knitted fabrics are produced by interlocking a series of loops made from one or more yarns. These fabrics are created using advanced industrial knitting machines.

Fabrics can be categorized based on the fibers they are made from:

Natural Fabrics 

Made from natural fibers like cotton, linen, and silk. These fabrics are often breathable, comfortable, and environmentally friendly.

Synthetic Fabrics

Made from synthetic fibers like polyester, nylon, and spandex. These fabrics are known for their durability, moisture resistance, and easy maintenance.

Blended Fabrics

Created by combining natural and synthetic fibers. These fabrics aim to combine the best properties of both types of fibers, offering a balance of comfort, durability, and versatility.

Understanding the Three Most Popular Fabric Types 

The three most commonly used fabrics in clothing are:

1. Cotton
2. Polyester
3. Blended Fabrics

Each of these fabrics has its unique characteristics, along with distinct advantages, disadvantages, and ideal applications. Let’s understand them in detail now.

1. Cotton Fabrics

Cotton is the world’s most extensively produced natural fiber. Renowned for its comfort and durability, it has become one of the most popular choices for clothing.

Characteristics of Cotton

Cotton is a natural fiber that has been used for thousands of years. It is known for its softness, breathability, and versatility. Here are some of the key characteristics of cotton:

• Softness: Cotton is one of the softest natural fibers, making it comfortable to wear against the skin. This makes it ideal for garments like t-shirts, underwear, and bed linens.
• Breathability: Cotton is highly breathable, allowing air to circulate and keeping the body cool. This makes it suitable for warm climates and activewear.
• Absorbency: Cotton is highly absorbent, which makes it effective at wicking away moisture from the skin. This is why cotton is commonly used in towels and athletic wear.
• Hypoallergenic: Cotton is less likely to cause allergic reactions, making it suitable for people with sensitive skin or allergies.
• Biodegradability: Cotton is a natural fiber that is biodegradable, making it an environmentally friendly choice.
• Maintenance: Cotton requires regular maintenance, as it can wrinkle easily and may shrink when washed. However, it is relatively easy to clean and can be machine washed.
• Softness: Cotton is one of the softest natural fibers, making it comfortable to wear against the skin. This makes it ideal for garments like t-shirts, underwear, and bed linens.
• Breathability: Cotton is highly breathable, allowing air to circulate and keeping the body cool. This makes it suitable for warm climates and activewear.
• Absorbency: Cotton is highly absorbent, which makes it effective at wicking away moisture from the skin. This is why cotton is commonly used in towels and athletic wear.
• Hypoallergenic: Cotton is less likely to cause allergic reactions, making it suitable for people with sensitive skin or allergies.
• Biodegradability: Cotton is a natural fiber that is biodegradable, making it an environmentally friendly choice.
• Maintenance: Cotton requires regular maintenance, as it can wrinkle easily and may shrink when washed. However, it is relatively easy to clean and can be machine washed.

Types of Cotton 

Cotton fabrics are available in various forms, each made from different types of fibers. Cotton clothing, including t-shirts, can be made from various types of cotton, including:

• Ringspun Cotton: Produced through a spinning process that straightens and thins each fiber, resulting in softer and more durable cotton. This process makes ringspun cotton more expensive than regular cotton.
• Combed and Ringspun Cotton: This type of cotton undergoes an additional combing process to remove impurities, making it even softer, less prone to fraying, and providing a smoother surface for printing. The extra processing increases its cost compared to ringspun cotton.
• Slub Cotton: Made by knotting and twisting the fibers, giving the fabric a textured feel and appearance. This texture allows the fabric to breathe better and reduces cling. Slub cotton is slightly more expensive than standard cotton.
• Pima Cotton: Known for its long fibers, Pima cotton is extremely soft, smooth, and resistant to wrinkling, making it a high-quality, but expensive, cotton.
• Pique Cotton: Woven in parallel cords or geometric shapes, giving it a raised look and feel, pique cotton is commonly used for polo t-shirts and can be made from Pima cotton. It tends to be more costly than other cotton types.
• Organic Cotton: Produced using sustainable methods without synthetic fertilizers or harmful pesticides, organic cotton can be softer and more durable than standard cotton but is also more expensive.

Pros

• Cotton clothing feels soft, comfortable, and gentle against the skin.
• Cotton is breathable, preventing fabric cling.
• Cotton is durable and biodegradable, with organic cotton being produced using eco-conscious methods.
• It is easy to print designs on cotton.

Cons

• Cotton absorbs moisture, leading to slow drying times.
• Cotton clothing wrinkles and shrinks, though preshrinking can mitigate this.
• Printed colors on cotton t-shirts may fade over time.
• Cotton is more susceptible to damage and stains.

Uses of Cotton

As the world’s favorite natural fiber, cotton boasts a wide array of applications. Its versatility, beauty, and comfort make it an excellent choice for apparel, bedding, textiles, and many other products. Whether we realize it or not, cotton plays a significant role in our daily lives.

• Clothing: Cotton is widely used in the production of various garments, including t-shirts, jeans, sweatshirts, dresses, and more.  it is a great choice for custom t-shirt printing.
• Woven Fabrics: This material is essential in creating a variety of woven fabrics like denim, damask, flannel, and others.
• Bed Sheets and Bedding: Cotton is a perfect choice for bedding due to its affordability, breathability, softness, and ease of care.
• Towels and Washcloths: Cotton's high absorbency makes it ideal for towels and washcloths.
• Underwear: The breathability of cotton makes it a comfortable option for undergarments, providing greater airflow.
• Home Décor: Cotton adds an attractive touch to home décor, being well-suited for curtains, carpets, rugs, upholstery, and more.
• Cottonseed Oil: A byproduct of cotton production, cottonseed is used to produce cottonseed oil, which can be utilized in salad oil, soaps, candles, cosmetics, and more.

These are just a few of the many products that can be made from cotton. It’s also used in items like tote bags, shoelaces, paper, and countless other practical products. In short, cotton has nearly limitless potential.

2. Polyester Fabrics

Polyester is a synthetic fiber created from petroleum-based materials. Invented in 1941, it’s relatively new compared to cotton. 

However, polyester has rapidly gained popularity in the fashion industry. It’s particularly favored by those who need a fabric that can endure frequent wear and washing. It is known for its durability, versatility, and low maintenance requirements. 

Characteristics of Polyester

Here are some of the key characteristics of polyester fabric:

• Durability: Polyester is one of the most durable fabrics available. It is resistant to stretching, shrinking, and abrasion, making it suitable for a wide range of applications, from clothing to industrial use.
• Wrinkle Resistance: Polyester resists wrinkling and retains its shape well, making it ideal for garments that need to maintain a crisp appearance.
• Moisture Resistance: Polyester is less absorbent than natural fibers, which makes it quick-drying and resistant to moisture-related issues like mildew and mold.
• Colorfastness: Polyester holds dyes well, resulting in vibrant, long-lasting colors. This makes it a popular choice for garments and home textiles that require bright, durable colors.
• Lightweight: Polyester is lightweight, making it comfortable to wear and easy to transport. This is particularly beneficial for outdoor and activewear.
• Heat Sensitivity: Polyester is sensitive to high temperatures and can melt if exposed to direct heat. It is important to use low heat settings when ironing or drying polyester fabrics.

Types of Polyester

Polyester is a versatile fabric which offers durability, versatility, and a range of textures and finishes, making it essential in both fashion and home furnishings.

• Knit Polyester: Stretchable and breathable, ideal for t-shirts, activewear, and leggings.
• Woven Polyester: Strong and durable, used in trousers, blazers, and outerwear.
• Polyester Fleece: Soft and insulating, perfect for jackets, hoodies, and blankets.
• Satin Polyester: Smooth and glossy with a luxurious sheen, commonly used in evening wear, lingerie, and home decor.
• Chiffon Polyester: Lightweight and sheer, great for dresses, blouses, and scarves.
• Crepe Polyester: Textured with a crinkled surface, used in suits, dresses, and skirts.
• Velvet Polyester: Plush and luxurious, ideal for evening wear, upholstery, and accessories.
• Taffeta Polyester: Crisp and smooth, used in formal wear, linings, and home decor.
• Organza Polyester: Sheer and stiff, perfect for wedding dresses and decorative overlays.
• Microfiber Polyester: Extremely soft and moisture-wicking, used in sportswear, bed linens, and cleaning cloths.

Pros

• Polyester keeps sweat away from the skin.
• Polyester dries quickly and is resistant to stains and odors.
• It resists wrinkling and shrinkage.

Cons

• Polyester fabric can be more expensive than cotton.
• It doesn't breathe as well as cotton and can cause static cling.
• Polyester fibers can irritate the skin and are not biodegradable.
• Silk screening is less effective on polyester than on cotton.

Uses of Polyester

Polyester is a versatile fabric that is used in a wide range of applications, thanks to its durability, moisture resistance, and colorfastness. Polyester is best suited for applications that require moisture resistance or durability, such as athletic wear or outdoor gear. Some of the most common uses of polyester include:

• Clothing: Polyester is widely used in the fashion industry for garments such as dresses, shirts, and activewear. Its wrinkle resistance and durability make it ideal for everyday wear.
• Home Textiles: Polyester is commonly used in home textiles like curtains, bed linens, and upholstery. Its colorfastness and resistance to wear and tear make it suitable for items that need to endure regular use.
• Outdoor Gear: Polyester is often used in outdoor gear, such as tents, backpacks, and sleeping bags, due to its lightweight and moisture-resistant properties.
• Industrial Applications: Polyester is used in various industrial applications, including conveyor belts, hoses, and safety belts, due to its strength and resistance to abrasion.
• Packaging: Polyester is used in packaging materials, such as plastic bottles and films, due to its durability and flexibility.
• Automotive Industry: Polyester is used in the automotive industry for seat belts, upholstery, and tires, thanks to its strength and resistance to wear and tear

3. Blended Fabrics

As you might expect, fabric blends are made by combining two or more different types of fibers to create a textile with distinct properties that leverages the best qualities of each component.

 Polyester-cotton blends are designed to combine the advantages of both fabrics.

Over the years, blended fabrics have been developed to meet specific needs, such as enhancing texture, durability, and comfort or even reducing production costs. 

Characteristics of Blended fabrics

Blended fabrics offer a balanced combination of the best qualities of each fiber, making them popular in fashion, home textiles, and technical applications. Some of these qualities include:

• Improved Strength and Durability: Blending strong synthetic fibers like polyester with natural fibers like cotton enhances the fabric's overall durability, making it more resistant to wear and tear.
• Enhanced Comfort: Natural fibers add softness and breathability, while synthetic fibers improve stretch and fit, creating a fabric that is both comfortable and functional.
• Better Moisture Management: Blends often improve moisture-wicking properties, making the fabric suitable for activewear and outdoor clothing.
• Wrinkle and Shrink Resistance: Synthetic fibers reduce the tendency of natural fibers to wrinkle and shrink, making blended fabrics easier to care for.
• Versatility: Blended fabrics can be tailored for specific needs, such as adding elasticity for a better fit in clothing or increasing warmth in winter garments.
• Cost-Effective: Blending fibers often reduces production costs, making high-quality fabrics more affordable.

Types of Blended Fabrics

• Polyester-Cotton (Polycotton): 

This is one of the most popular blends, combining the softness and breathability of cotton with the durability and wrinkle resistance of polyester. Polycotton is widely used in everyday clothing, uniforms, and bed linens. The blend ratio can vary, typically ranging from 50/50 to 65/35 (polyester/cotton), with the exact mix tailored to balance comfort, durability, and cost.

• Wool-Polyester: 

This blend combines the warmth and natural insulation of wool with the strength and wrinkle resistance of polyester. It’s often used in suiting and outerwear, providing a fabric that is warm, durable, and easier to care for than pure wool.

• Lycra-Cotton: 

Lycra (also known as spandex or elastane) is blended with cotton to create fabrics that are stretchy and comfortable. This blend is commonly used in activewear, leggings, and fitted garments that require flexibility and a snug fit.

• Rayon-Polyester: 

Rayon, a semi-synthetic fiber made from cellulose, is often blended with polyester to create fabrics that are soft, smooth, and durable. This blend is popular in fashion, offering a luxurious feel with the practical benefits of easy care.

• Nylon-Wool: 

This blend is used in technical and outdoor fabrics, combining the durability and moisture-wicking properties of nylon with the warmth and natural resistance to odors of wool. It's ideal for activewear and outdoor gear.

Most popular blends

Today, there are countless fabric blends on the market, but some of the most popular blends for printed apparel include:

• Cotton-Polyester Blends (65/35 and 50/50):
  If you can't choose between cotton and polyester, a cotton-polyester blend offers the best of both worlds. These blends are versatile, used in everything from bedding to shirts. Polyester's resistance to shrinking and shape changes makes these blends easier to wash and dry, while the cotton content adds breathability, making them superior to pure polyester. Plus, this blend provides an excellent canvas for bright, colorful designs. These blends are the most common polyester-cotton blends used for clothing items such as t-shirts.
• Polyester-Cotton-Rayon Blends (50/25/25):
  Rayon, a semi-synthetic fiber, combines the best qualities of polyester, cotton, and rayon. Apparel made from this blend is soft, stretchy, and durable, making it perfect for loose-fitting clothing with a cozy feel. The looser weave and fabric combination give DTG prints on tri-blends a vintage look, with the garment's fabric slightly showing through the ink.
• Polyester-Spandex Blends (85/15):
  Spandex, also known as elastane or lycra, is a synthetic fiber famous for its elasticity. When blended with cotton, it creates a fabric that is both soft and durable. Polyester-spandex blends are particularly popular in activewear because spandex provides stretch and shape retention, while polyester adds durability.

Advantages of Blended Fabrics

• Enhanced Durability: Blending a synthetic fiber like polyester with a natural fiber like cotton can significantly enhance the fabric's strength and longevity.
• Improved Comfort: Blends can be engineered to offer the softness of natural fibers with the added benefits of elasticity or moisture management from synthetic fibers.
• Cost Efficiency: Blending expensive natural fibers with less costly synthetics can make high-quality fabrics more affordable.
• Versatility: Blended fabrics are often more versatile, suitable for a broader range of uses compared to pure fabrics.
• Special Properties: Blends can be designed to offer specific properties like wrinkle resistance, quick-drying, or enhanced stretch, making them suitable for various specialized applications.

Pros

• Polyester-cotton blends offer the benefits of both fabrics while reducing the cost of pure polyester.
• Blended fabrics provide the soft comfort of cotton.
• Blended fabric t-shirts dry quickly, resist shrinking, and are durable.

Cons

• Blended fabrics can be more expensive than pure fabrics.
• High-cotton-content blends shrink more than high-polyester blends.
• Blended fabrics are not biodegradable.
• High-polyester-content blends are less suitable for silk screening.

Uses of Blended Fabrics

Blended fabrics are versatile and widely used across various industries. Here are some common uses:

• Apparel:
  • Casual Wear: T-shirts, hoodies, and sweatshirts often use cotton-polyester or tri-blends for comfort and durability.
  • Activewear: Polyester-spandex blends are popular for sportswear, yoga pants, and leggings due to their stretch and moisture-wicking properties.
  • Workwear: Cotton-polyester blends are used in uniforms and workwear for their durability and easy care.
• Home Textiles:
  • Bedding: Cotton-polyester blends are common in sheets, pillowcases, and duvet covers for a balance of softness and durability.
  • Upholstery: Blended fabrics are used in sofas, chairs, and cushions for improved wear resistance and comfort.
• Outdoor Gear:
  • Jackets and Coats: Blended fabrics like polyester-cotton blends offer weather resistance and durability, making them ideal for outerwear.
  • Sleeping Bags: Blends are used to provide warmth, durability, and moisture resistance in outdoor gear.
• Footwear:
  • Shoes: Blended fabrics are used in sneakers and other footwear to provide flexibility, durability, and breathability.
• Accessories:
  • Bags and Luggage: Blended fabrics like polyester-cotton or polyester-nylon are used for their strength and resistance to wear and tear.
  • Hats and Caps: Blends are used in headwear for comfort and durability.
• Industrial Applications:
  • Protective Clothing: Blended fabrics are used in safety gear and uniforms for their flame resistance, durability, and comfort.
  • Automotive: Seat covers and interior upholstery often use blended fabrics for their durability and ease of cleaning.
• Medical Textiles:
  • Scrubs and Lab Coats: Cotton-polyester blends are common in medical uniforms for their comfort, durability, and easy maintenance.

Cotton vs. Polyester 

Cotton and polyester are two of the most widely used fabrics in the world. While they may appear similar at first glance, they have distinct differences that affect their performance, feel, and application.

Cotton vs. Polyester vs Blends

Let’s compare cotton, polyester and blends on the basis of comfort, durability and printing technique suitable for them.

Conclusion

Choosing the right fabric is essential, whether you’re a clothing retailer, a designer, or someone who simply wants to understand textiles better. Cotton, polyester, and blended fabrics each have their own unique characteristics that make them suitable for different applications. 

Cotton is beloved for its softness, breathability, and natural feel, making it ideal for everyday wear and items close to the skin. 

Polyester, on the other hand, stands out for its durability, moisture resistance, and low maintenance, making it a go-to choice for activewear and outdoor gear. 

Blended fabrics offer the best of both worlds, combining the strengths of natural and synthetic fibers to create versatile, durable, and comfortable textiles.

By understanding the properties and uses of these fabrics, you can make more informed decisions in your business or personal projects. Whether you prioritize comfort, durability, or cost-efficiency, there’s a fabric out there that meets your needs. As the textile industry continues to innovate, the range of options will only expand, providing even more opportunities to create and enjoy high-quality, tailored products.