How to Choose the Perfect T-Shirt Fabric for Printing
Choosing the right t-shirt fabric is one of the most important decisions you’ll make when planning a merch drop, brand launch, or custom print order. Even the best artwork can lose impact if the fabric isn’t suited to the print method.
The wrong material can cause cracking, fading, warping, or a print that never looks as sharp as it should. The right fabric, on the other hand, makes the design pop, feel premium, and last longer for the wearer.
At Halo Print Co, we help brands and businesses across Sydney choose t-shirt fabrics every day, and the choice always comes down to what you’re printing, how you want it to look, and who’s going to wear it. This guide breaks down the most common fabrics, what they’re best for, and how to pick the perfect one for your print.
Why Fabric Matters for Print Quality
It’s not just about comfort, fabric determines how crisp or soft the print appears, how colours absorb and hold vibrancy, whether details stay sharp or get textured, how long the print lasts after washing, and how the shirt fits into the brand’s aesthetic. If you’re aiming for high-quality merch or retail-ready apparel, fabric choice isn’t a small detail, it’s step one.
100% Cotton: The Most Popular Choice for Printing
For most print projects, 100% cotton is the go-to option. It’s breathable, smooth, and absorbs ink extremely well. It’s perfect for DTG printing, screen printing with bold colours, flash sheet designs, fine lines, and high detail.
Cotton works because ink binds cleanly to natural fibres, colours appear rich, it suits both large prints and intricate detail, and it works on light or dark garments. If you’re unsure where to start, cotton is usually the safest, most versatile choice.
Heavyweight Cotton: For Premium & Streetwear Merch
Heavyweight cotton has become a favourite for premium and streetwear-style prints. It’s thicker, structured, and holds shape well after washing. This is ideal for large back prints, tattoo merch, bold artwork, and shirts that need to feel premium. If you’re pricing merch at retail value, heavyweight cotton creates a strong first impression and increases perceived value.
Cotton Blends (80/20, 60/40, 65/35)
Cotton blends mix natural fibres with polyester or elastane. They’re soft, lightweight, and cost-effective, but they won’t hold detail like cotton. They work well for uniforms, gym/work apparel, or simple logo prints. If detail and clarity matter most, pure cotton is often the better option, but blends are great when budget or comfort is the priority.
Polyester & Performance Fabrics
Polyester is common in sportswear and workwear. It’s smooth and durable, but it doesn’t absorb ink the same way cotton does. Screen printing works well; DTG may struggle on polyester. Use polyester for sports teams, activewear, and workplace apparel, not for detailed, artistic prints like flash sheets or realism.
How to Choose Based on Print Method
DTG Printing: 100% cotton, mid or heavyweight
Screen Printing: Cotton or blends, works across most fabrics
Embroidery: Heavyweight cotton or blends for structure
Large Back Prints: Heavyweight cotton for shape retention
If you don’t know which method suits your artwork, the design usually decides it for you.
How to Know Which Fabric Is Right For You
If the artwork is detailed → choose cotton.
If the product needs a premium feel → heavyweight cotton.
If it’s bulk or budget-focused → blends.
If it’s for sport or movement → polyester.
If it’s streetwear or retail merch → heavyweight or oversized cotton.
Bring in your artwork, and Halo Print Co will recommend the best match.
Final Thoughts
Fabric choice isn’t just a technical detail, it’s a branding decision. The right shirt can elevate your artwork, increase sales, and make customers want to wear it again and again. Whether this is your first merch run or your next big drop, choosing the right foundation makes every print better.
Ready to choose the right shirt for your design? Order your prints with Halo Print Co and get personalised fabric recommendations for your artwork.
