How to Choose the Right Fabric for Your Custom Apparel
You’ve nailed your design. You know whether you want DTG or DTF printing. But there’s one more critical decision that can make or break your custom apparel project: choosing the right fabric.
The fabric you select affects everything—print quality, durability, comfort, cost, and how your customers feel wearing your gear. Pick the wrong one, and even the best design won’t save you.
After 28 years in the printing business, I’ve seen how fabric choice impacts the final product. Whether you’re creating band merch, branded corporate wear, or testing a new design as a reseller, understanding custom apparel in Calgary starts with understanding fabric.
Let’s break down how to choose the right fabric for your project.
Why Fabric Choice Matters
Not all fabrics are created equal. The material you choose impacts:
- Print quality: Some fabrics hold ink better than others
- Durability: How well the print withstands washing and wear
- Comfort: Breathability, softness, and fit
- Cost: Premium fabrics cost more but may offer better value long-term
- Printing method compatibility: Cotton loves DTG printing; polyester shines with DTF
According to Cotton Incorporated, fabric choice is the #1 factor consumers consider when purchasing apparel—even above price.
The Most Popular Fabric Types for Custom Apparel
1. 100% Cotton
Best For: Soft, breathable everyday wear; ideal for DTG printing
Pros:
- Extremely soft and comfortable
- Breathes well—great for warm weather
- Holds DTG ink beautifully with vibrant colors
- Natural, eco-friendly fiber
Cons:
- Can shrink if not pre-shrunk
- Wrinkles more easily than blends
- May fade slightly over time with heavy washing
Recommended For: Band merch, casual wear, retail apparel, promotional giveaways
2. Cotton/Polyester Blends (50/50 or 60/40)
Best For: Durability and shape retention; works with both DTG and DTF
Pros:
- More durable than 100% cotton
- Resists shrinking and wrinkling
- Holds shape better after multiple washes
- Often more affordable
Cons:
- Slightly less soft than pure cotton
- Can pill over time with heavy wear
- DTG prints may not be as vibrant as on 100% cotton
Recommended For: Corporate apparel, sports teams, workwear, budget-conscious projects
3. 100% Polyester
Best For: Performance wear, athletic apparel; best with DTF printing
Pros:
- Moisture-wicking and quick-drying
- Extremely durable and colorfast
- Resists shrinking and stretching
- Perfect for DTF printing—vibrant, long-lasting prints
Cons:
- Less breathable than cotton
- Can feel synthetic or “plasticky”
- Not ideal for DTG printing (can cause dye migration)
Recommended For: Sports jerseys, activewear, outdoor gear, performance apparel
4. Tri-Blends (Cotton/Polyester/Rayon)
Best For: Premium, ultra-soft retail apparel
Pros:
- Incredibly soft with a vintage feel
- Drapes beautifully on the body
- Lightweight and breathable
- Great for high-end retail or fashion-forward designs
Cons:
- More expensive than standard fabrics
- Can be trickier to print on (requires experienced printer)
- May shrink slightly
Recommended For: Premium band merch, boutique retail, fashion brands
How to Match Fabric to Your Printing Method
For DTG Printing:
- Best: 100% cotton or high-cotton blends (80%+ cotton)
- Why: DTG ink bonds beautifully with natural cotton fibers for soft, vibrant prints
- Avoid: 100% polyester (risk of dye migration and poor ink adhesion)
For DTF Printing:
- Best: Polyester, poly-blends, performance fabrics
- Why: DTF transfers adhere to synthetic fibers with excellent durability and color
- Works on: Cotton too, but truly shines on polyester
Not sure which method to use? Check out our guide on DTG vs. DTF printing.
Other Fabric Factors to Consider
Weight (GSM – Grams Per Square Meter)
- Lightweight (130-150 GSM): Breathable, great for summer or layering
- Midweight (160-180 GSM): Standard t-shirt weight; versatile year-round
- Heavyweight (200+ GSM): Premium feel, durable, great for hoodies and winter wear
Fit and Style
- Classic fit: Relaxed, traditional t-shirt shape
- Slim fit: Tapered, modern silhouette
- Oversized/boxy: Trendy streetwear style
Consider your audience. Bands might want slim or oversized fits; corporate clients typically prefer classic.
Pre-Shrunk vs. Non-Pre-Shrunk
Always choose pre-shrunk fabrics to avoid size changes after the first wash. Most quality blanks from suppliers like Gildan or SanMar are pre-shrunk.
Quick Fabric Selection Guide
| Project Type | Recommended Fabric | Printing Method |
|---|---|---|
| Band Merch | 100% Cotton or Tri-Blend | DTG |
| Corporate Apparel | 50/50 Cotton/Poly Blend | DTG or DTF |
| Sports Teams | 100% Polyester | DTF |
| Retail/Resale | 100% Cotton or Tri-Blend | DTG |
| Promotional Giveaways | 50/50 Blend (budget-friendly) | DTG or DTF |
| Activewear | 100% Polyester | DTF |
Copy table
The Bottom Line: Choose Fabric Based on Your Goals
There’s no “best” fabric—only the best fabric for your specific project.
Ask yourself:
- Who’s wearing this? (Comfort preferences, activity level)
- How long does it need to last? (Durability requirements)
- What’s your budget? (Premium vs. value options)
- What printing method are you using? (DTG vs. DTF compatibility)
At DTG Printing Corp, we help Calgary businesses, bands, and resellers choose the perfect fabric for their custom apparel in Calgary projects. With 28 years of experience, we know which fabrics work best for every design, budget, and printing method.
Need help choosing the right fabric?Contact us today for expert advice, or submit your order and we’ll guide you through the process.