Guide to Polyester, Cotton, and Blended Fabrics (2024)

Whether you’re just starting out or have been in the print-on-demand business for a while, learning or refreshing your knowledge of cotton and polyester fabrics never hurts.

Fabric choices matter. The composition of the garment is arguably the most important factor when it comes to selling apparel.

Each fabric has different properties. The garment might look absolutely amazing, but if the fabric is low quality, wears out easily, or shrinks excessively, it won’t appeal to your customers.

After reading this article, you’ll have a better understanding of different types of fabrics, their characteristics and functionality. We will lightly touch on how cotton and polyester are made and see why sometimes blended fabrics are the way to go.

This knowledge will help you choose the most appropriate fabric for your brand and make the best use of it.

• What Is a Fiber?
• What Is a Fabric?
• Cotton vs. Polyester
• What Are the Characteristics of Polyester Fabric?
• The Many Uses of Polyester
• What Are the Characteristics of Cotton?
• Four Different Types of Cotton
• The Many Uses of Cotton
• What Are Blended Fabrics?

In the textile industry, fiber, or fibre, is a material mainly made from natural or synthetic sources. The raw materials are turned into fiber, but fiber itself is spun into yarns, which then are woven or knit to make fabrics.

All fibers are classified by their chemical origin into two groups.

• Natural Fibers. They’re made out of natural materials that come from plants (cotton, flax, linen, etc.), animals (wool, silk, mohair, etc.), or minerals. Mineral fibers, however, are not commonly used in textile manufacturing.
• Synthetic Fibers. These are made by humans through chemical processes. Some examples of these fibers are polyester and its synthetic siblings – nylon, acrylic, spandex, etc.

As stated previously, fibers are the cornerstone of all clothing. Then comes the yarn. A yarn is a continuous length of interlocked fibers. It is used for the production of woven and knitted fabrics or thread for sewing, embroidery, and crocheting. In short, fabric is the raw material from which clothes and other items are made.

Although there are many, the two main processes of making fabric from yarn are:

• Weaving. Interlacing two sets of yarns so that they cross each other, usually at right angles.
• Knitting. Knitted fabrics are made by interlocking a series of loops made from one or more yarns. Knitted fabrics are manufactured on highly sophisticated industrial knitting machines.

Although cotton is the most widely used natural fiber, polyester is the most popular synthetic fabric in the world. They are both go-to fabrics for clothing, accessories, and home décor. Each has its own distinct qualities and uses.

What is the main difference between cotton and polyester? In short, the difference lies in how they are made and what their characteristics are. Polyester vs. cotton – which is better? It all depends on your needs and what kind of product you want to make.

Read on as we dig deeper to learn more about their particular benefits and disadvantages.

• Lightweight. Polyester fabric is well suited for a wide variety of sports. Excellent for activewear clothing and demanding outdoor activities.
• Extremely Durable. Due to polyester’s incredibly strong fibers, it’s known as the workhorse of fitness fabrics.
• Moisture-Wicking. This material is naturally water-resistant, but not waterproof. The polyester fabric will wick moisture away.
• Easy to Care For. Polyester fibers do not wrinkle, and dry quickly. If it’s left outside in direct sunlight and open air, it can dry in an hour or less.

• Feels Coarse. There are different types of polyester. Some polyester fibers feel coarse, rough, and even slippery against your skin, but others, like China silk, are almost as smooth as satin.
• Typically Non-biodegradable. Though polyesters and other synthetic fabrics will eventually break down, it might take from 20 to 200 years.
• Melts Under Heat. While some polyester fabrics have a high burning point, it melts more easily than you think. It should not be worn while working in the kitchen or near an open flame.
• Mostly Non-breathable. Garments made out of polyester are not naturally breathable, but some polyester fabrics are manufactured specifically to provide breathability.

Polyester fabric is prized for its relative affordability, strength, and wrinkle resistance. Although it’s water-resistant, it’s not completely waterproof until it has been treated with water repellent or coated with a layer of extra fabric.

These, and other polyester characteristics previously mentioned, are why this synthetic fabric is the most popular fiber for clothing. However, polyester fabric is also used to make many different products.

Due to polyester’s highly functional fiber, it’s well suited for making a vast array of garments.

Most common uses:

• Fashion and high-end fashion products
• Sportswear, activewear, footwear
• Jackets, coats, anoraks
• Fleece, sheets, duvet covers, sleeping bags
• Military clothing
• Soft furniture and upholstery, luggage and other bags, rugs, carpets, etc.

Additionally, there are also industrial polyester fibers that are used to make things like seat belts, conveyor belt fabrics, plastic reinforcements, and many other items.

Polyester fabric has an immense variety of practical uses in many different sectors. Today, technological advances keep improving the feel, drape, and look of polyester.

Some of our customizable items that are made from polyester:

• Spun Polyester Lumbar Pillow

Whatever your goals, our mission stays the same – to help people make more money with less effort. With Printify, you can start your own business without any up-front costs. What’s more, our powerful Mockup Generator allows you to easily create real products. Afterwards, we take care of everything – printing, inventory, and shipping.

The best part is that registering is completely free, and you can order as few or as many items as you like.

• Comfortable. Fabric made out of cotton is very soft and comfortable. It is one of the best fabrics for hot weather. It stays cool in summer and allows you to keep your zen throughout the day.
• Durable. Although it’s not as tough as polyester, cotton is a relatively strong and wear-and-tear resistant fabric.
• Biodegradable. This material is renewable and biodegradable. However, it is extremely water-intensive and consumes more pesticides than any other single crop.
• Breathable. Due to its breathability, absorbency, and hypoallergenic nature, cotton is often used for custom underwear, socks, and other garments that are worn close to the skin.

• Low Resilience. Some products made from cotton crease badly and may not recover well. It also shrinks after washing and stains easily.
• Flammable. Cotton catches fire easily and burns rapidly.
• Susceptible to Mildew. Mildew causes rotting and degradation. Although anti-mildew finishes can be applied, if you are going to use this fabric in a humid environment, then it's not the best choice.
• Absorbs a Lot of Moisture. This can be both a positive and negative quality, depending on the circ*mstances. It is great in summer, but may be dangerous in windy and cold conditions – it dries slowly, so you stay wet and cold, which can lead to hypothermia.

As one of the most popular natural fibers, cotton is grown commercially all around the world. Due to its excellent qualities, it has been used since ancient times to create a variety of products.

These are the most common:

The world’s favorite natural fiber has a wide range of applications. Due to its versatility, beauty and comfort, cotton is an ideal choice for apparel, bedding, textiles, and many other products. Whether we know it or not, it’s part of our daily lives.

Common uses:

• Clothing. Cotton is a popular fabric that is used to make various clothing. It is frequently used for t-shirts, jeans, sweatshirts, dresses, and many other items.
• Woven Fabrics. This material is used to make a variety of woven fabrics – denim, damask, flannel, and more.
• Bed Sheets and Bedding. Perfect for the bedroom. Cotton is an affordable luxury – breathable, soft, and easy to care for.
• Towels and Washcloths. Cotton is highly absorbent, which makes it ideal for towels.
• Underwear. Since cotton is breathable and provides greater airflow, it’s a comfy choice for undergarments.
• Home Décor. Attractive throughout the home. Well suited for curtains, carpets, rugs, upholstery, and much more.
• Cottonseed Oil. Cottonseed is a byproduct of the cotton production process. The seeds are used to manufacture cottonseed oil, which can be used to make salad oil. It can also be used in soap, candles, cosmetics, and more.

These are just a few things that you can make with cotton. It can also be used to make tote bags, shoelaces, paper, and many other practical products. In short, cotton has almost limitless potential.

Take a look at some of our customizable items that are made from cotton:

• Unisex Ultra Cotton Tee
• Tea Towel
• Cotton Tote Bag

If polyester and cotton are blended together, you get poly cotton. By blending, it’s possible to produce fabrics that exhibit properties unachievable with either fiber alone.

With these blends, manufacturers are able to make clothing that’s stronger, more customizable, and more versatile than pure cotton. Poly cotton combines the best of both worlds – the moisture-wicking ability of polyester with the breathability of cotton.

If you can’t choose between cotton or polyester, let’s look at their blends and see whether one of these would better fit your brand and needs.

These days, a split between these two fabrics is a common sight. They’re popular because they provide a healthy balance between breathability, durability, comfort, and price.

Take a look at some of our customizable items that are made from blended fabrics:

• Unisex Heavy Blend™ Hooded Sweatshirt
• Champion Sweatshirt
• Premium Fleece Joggers

In the world of fiber, neither is better. The truth is – they both have their advantages and drawbacks. Neither of them will ever replace the other. On the contrary, by blending these fabrics together, they complement each other in many wonderful ways.

It is all about being savvy when it comes to picking your fabric – the more you know, the better choices you can make. If you do your research, there’s no reason why you, cotton, polyester, and their blends can’t all be friends.