What is the best material to print shirts on?

What’s the Best Material to Print Shirts On? 

We talk about custom shirts a lot, but choosing the right fabric is still one of the biggest things people overlook. It’s not just cost or style. The material you pick determines how the print looks, how the shirt feels, and how long it holds up. 

Common Shirt Printing Methods

Before you even think about cotton vs. polyester, it helps to understand how shirts get printed, because the printing method and the fabric go hand in hand.

1. Screen Printing

Screen printing is the classic method, ink is pushed through a mesh screen onto the fabric.

2. DTG (Direct-to-Garment) Printing

Think of DTG like a giant inkjet printer for shirts.

3. DTF (Direct-to-Film) Printing

Your design is printed onto a film, covered with adhesive powder, then heat-pressed onto the shirt.

4. Sublimation

Sublimation turns ink into vapor and bonds it into polyester fibers.

Here’s what matters when choosing fabric

1. Print Quality

Not all fabrics behave the same when ink hits them. Some absorb better, others let the ink sit on top. That affects color vibrancy, detail, and durability.

2. Comfort & Wearability

How the shirt feels depends on the fibers. Cotton feels different than poly, and blends give you a middle ground.

3. Durability

Fabric choice determines how the shirt holds up: Will it wrinkle after a wash? Will it shrink? Will the design crack or fade over time?

4. Intended Use

Are these merch shirts? Uniforms? Athletic wear? Your end goal should guide the material: you don’t need the same fabric for performance tees as for company uniforms.

Now Let’s Talk Fabrics and the Best Printing Method for Each

100% Cotton

Cotton is soft, breathable, and the most forgiving fabric for printing.

Best printing methods:

• Screen Printing (excellent adhesion, vibrant colors)

• DTG (cotton absorbs the ink perfectly)

• DTF (good, but screen/DTG outperform)

• Avoid: Sublimation, it won’t work on cotton.

Cotton/Poly Blends (50/50 or Triblends)

Blends balance comfort, durability, and stretch.

Best printing methods:

• Screen Printing (inks sit well across blended fibers)

• DTF (great consistency on blends)

Use with caution:

• DTG can work, but colors may dull on polyester.

• Sublimation only partially bonds unless the polyester content is high.

100% Polyester

Poly is king for athletic and performance apparel.

Best printing methods:

• Sublimation (the gold standard for polyester)

• DTF (very good alternative)

• Avoid: DTG, ink won’t absorb well.

Triblends (Cotton, Polyester, Rayon)

Softest option on the market, but tricky for printing.

Best printing methods:

• DTF (handles mixed fibers best)

• Screen Printing (works, but colors may mute slightly)

• Avoid: Sublimation (rayon does not sublimate well).

Heavyweight or Ringspun Cotton

Premium feel, smooth surface, long-lasting.

Best printing methods:

• Screen Printing (exceptional detail and longevity)

• DTG (ringspun is ideal for crisp prints)

If you’re designing a shirt and not sure which fabric to choose, contact us. We can help you pick the right shirt for your design and budget, and make sure what you print looks and feels exactly how you want it to.