If you’re running an apparel brand — whether as a business owner, a creator, or even managing merch for a community — one of the biggest decisions you’ll face is choosing the right fabric.

While designs, colors, and cuts matter, the fabric defines how your product feels, wears, and sells. And in the world of merch and apparel, two materials dominate the conversation: Cotton and Polyester.

So, how do you choose? Let’s break it down.

Cotton: The Timeless Favourite

Cotton has been a staple in the textile industry for centuries. It’s loved for its natural feel, breathability, and versatility.

Why Brands Love Cotton:
Comfort and Softness: Perfect for everyday wear, cotton feels gentle against the skin.
Breathable: Keeps you cool, making it great for warm weather or casual clothing.
Versatile Thickness: Comes in various GSMs (Grams per Square Meter), like 180 GSM, 220 GSM, 240GSM and 260 GSM letting you choose lighter or thicker fabrics.
Perceived Value: Customers often associate cotton with premium quality.

Common Uses:
Lifestyle and streetwear brands
Polo T-shirts for casual or semi-formal use
Merch drops where comfort and feel matter

Pricing:
Generally higher than synthetic fabrics.
Non-branded cotton polos can range between ₹320-440.
Branded options go up to ₹630-900 or more.

Considerations:
Not always ideal for heavy-duty sportswear or high-performance use.
May not support all types of advanced printing techniques as seamlessly as synthetics.

Polyester: The Modern Power Player

Polyester entered the apparel scene as a synthetic alternative, known for durability and performance properties.

Why Brands Love Polyester:

Durability: Holds its shape and color over time.
Moisture-Wicking: While not always as breathable, polyester excels at keeping moisture away from the skin — perfect for sports.
All-Over Printing: Supports sublimation printing, creating vibrant, wrap-around designs without cracking or peeling.
DTF Printing: Works beautifully with Direct-to-Film techniques, allowing soft, durable prints that integrate into the fabric.

Common Uses:
Activewear and sports jerseys
Uniforms for teams or corporate events
Large-scale event merchandise where durability and bright prints matter
Lower-cost bulk orders

Pricing:
Hoodies can range from ₹749 to ₹2199 plus GST and branding costs.
Often more budget-friendly for large volumes.

Considerations:
Not as naturally breathable as cotton.
Some consumers still prefer the “natural” feel of cotton.

Understanding Your Audience

Here’s the single biggest piece of advice: Know who you’re selling to. Let’s say you run a tennis coaching academy:

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  You’d likely create polyester jerseys for players to wear during training and matches. They’re durable, moisture-wicking, and ideal for sports.

  
  


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  You might also launch cotton-based merchandise — think tennis-themed tees or polos — for fans and families who want tennis-related apparel for casual use.

  
  

It’s not about which fabric is “better.” It’s about which fabric fits your customer and your use case.

When to Choose Cotton:
Premium feel and comfort matter most.
Merch is meant for everyday or casual wear
Your audience values natural fibers and softness.
You’re focused on smaller runs or custom orders.

When to Choose Polyester:
Products are for active or high-movement use.
You want vibrant, all-over prints (sublimation).
Budget and volume efficiency are key.
Durability and washability are critical.

Final Thoughts

Cotton and polyester each have a place in modern apparel. The smartest brands often use both — picking the right fabric for the right product line and audience.

At Your Design Store, we help creators and businesses navigate these choices every day. Whether you’re launching your first drop or your fiftieth, we’re here to help you choose the right fabric and printing method for your vision.

Want to dive deeper? Talk to us here — or check out how we help brands bring their ideas to life.