How to Choose the Right Fabric for Screen Printing and Embroidery
Posted by Integrity Branding on Mar 3rd 2025
When ordering custom apparel, choosing the right fabric is just as important as the design itself. The fabric type plays a critical role in print clarity, embroidery detail, durability, and overall comfort. Whether you're customizing bulk t-shirts, corporate uniforms, athletic gear, or promotional apparel, selecting the right material ensures your prints remain vibrant and your embroidery stays intact over time.
This guide explores the best fabric options for both screen printing and embroidery, detailing their pros and cons, ideal use cases, and how to maintain quality over time.
Why Fabric Choice Matters in Custom Printing & Embroidery
The type of fabric used in custom apparel affects several key factors:
✔ Print Quality: Some fabrics absorb ink better, while others require special printing techniques.
✔ Embroidery Performance: Stitches need a stable, smooth surface to ensure detail and durability.
✔ Durability & Comfort: Certain fabrics hold up better after multiple washes and offer breathability.
✔ Cost Efficiency: Bulk orders can vary in price based on the fabric type.
By understanding how different fabrics interact with printing and embroidery methods, businesses can optimize their bulk orders for longevity, style, and comfort.
Best Fabrics for Screen Printing
1. 100% Cotton – The Classic Choice
Best for: T-shirts, hoodies, tote bags, and promotional apparel
Cotton is the most popular fabric for screen printing due to its soft texture, breathability, and excellent ink absorption. It delivers bold, vibrant prints with crisp edges.
✔ Pros:
- Holds ink well, producing bright and long-lasting designs
- Soft, breathable, and comfortable for all-day wear
- Works with various ink types, including water-based and plastisol inks
✖ Cons:
- Can shrink when washed (opt for pre-shrunk cotton to prevent this)
- Prone to wrinkles and may fade faster than synthetic fabrics
✅ Best Uses: Custom t-shirts, event giveaways, eco-friendly branded items.
2. Cotton-Polyester Blends – Durability Meets Comfort
Best for: Corporate uniforms, team apparel, and everyday workwear
Blending cotton with polyester improves durability while maintaining comfort. This fabric is less prone to shrinking and wrinkling, making it ideal for bulk orders requiring long-term use.
✔ Pros:
- More durable and wrinkle-resistant than pure cotton
- Retains color and shape after multiple washes
- Feels soft but holds ink well for bold prints
✖ Cons:
- Some blends resist water-based inks
- Colors may appear slightly muted compared to 100% cotton
✅ Best Uses: Work uniforms, retail apparel, and casual wear.
3. 100% Polyester – Ideal for Performance Wear
Best for: Sports jerseys, activewear, and moisture-wicking apparel
Polyester is a synthetic fabric designed for durability and performance. It’s commonly used in athletic and corporate wear, where moisture-wicking and longevity are essential.
✔ Pros:
- Resistant to shrinking, wrinkling, and fading
- Works well with sublimation printing for full-color, long-lasting designs
- Moisture-wicking properties keep wearers cool and dry
✖ Cons:
- Standard screen printing ink may not adhere well (requires special inks)
- Not as breathable as natural fabrics
✅ Best Uses: Sports uniforms, branded fitness apparel, and outdoor workwear.
4. Tri-Blend Fabrics – Premium Comfort & Style
Best for: High-end retail apparel, boutique t-shirts, and luxury promotional wear
A tri-blend combines cotton, polyester, and rayon, offering exceptional softness, durability, and a vintage-style drape. These materials are commonly used in fashion-focused merchandise.
✔ Pros:
- Ultra-soft and lightweight, providing premium comfort
- Creates a fashionable heathered look
- Holds screen printing ink well while retaining a smooth texture
✖ Cons:
- Higher cost compared to cotton and polyester blends
- Less vibrant colors due to the blended fibers
✅ Best Uses: High-end promotional items, company swag, retail apparel.
Best Fabrics for Embroidery
Unlike screen printing, embroidery requires a stable and durable fabric that can hold stitches without puckering. Here are the top fabric choices for embroidery:
1. Cotton Twill – Best for Structured Apparel
✔ Used for hats, uniforms, and workwear
✔ Holds stitches well without distortion
✔ Durable and long-lasting
2. Polyester Blends – Wrinkle-Resistant & Durable
✔ Great for jackets, corporate polos, and promotional gear
✔ Smooth surface allows for detailed embroidery designs
✔ Resists shrinking and maintains shape over time
3. Fleece & Sweatshirts – Ideal for Winter Apparel
✔ Works well for hoodies, sweatshirts, and pullovers
✔ Requires stronger backing material to keep stitches secure
✔ Thick fabric adds depth and dimension to embroidered logos
4. Denim & Canvas – Heavy-Duty and Stylish
✔ Perfect for branded tote bags, aprons, and outerwear
✔ Strong enough to hold large, intricate embroidery designs
✔ Highly durable, making it great for long-term branding
How to Choose the Right Fabric for Your Custom Order
When deciding on the best fabric for your screen-printed or embroidered apparel, consider these key factors:
1️⃣ Purpose: Will the apparel be used for events, corporate uniforms, athletic gear, or giveaways?
2️⃣ Comfort: If people will be wearing it daily, choose soft, breathable fabrics like cotton or blends.
3️⃣ Durability: For long-term use, polyester blends and twill fabrics hold up better over time.
4️⃣ Printing vs. Embroidery: Cotton and blends work best for screen printing, while structured, thicker fabrics are ideal for embroidery.
5️⃣ Budget: Higher-quality fabrics cost more but offer greater durability and a premium feel.
Caring for Your Printed & Embroidered Apparel
Once you’ve selected the perfect fabric, proper care ensures your designs last longer.
? Washing Tips:
- Wash in cold water to preserve ink and thread integrity.
- Turn garments inside out to prevent direct friction.
- Use mild detergents and avoid harsh chemicals.
? Drying & Ironing:
- Air dry when possible or use low heat settings in the dryer.
- Avoid high heat when ironing—use a cloth over embroidered designs to protect the stitching.
Final Thoughts: Get the Perfect Fabric for Your Custom Order
Choosing the right fabric for screen printing and embroidery ensures your custom apparel looks great, feels comfortable, and lasts longer.
At Integrity Branding, we specialize in high-quality bulk screen printing and embroidery, helping businesses, teams, and organizations create custom apparel that stands out.
? Need help selecting the best fabric for your order? Contact us today for expert recommendations and a free quote!