When choosing between polyester blend and 100% cotton fabrics, one must consider factors like feel, longevity, and suitability for printing techniques like screen printing and Direct-to-Garment (DTG) printing. This comparison sheds light on the distinct qualities and advantages of each fabric type.

Polyester blend shirts, particularly popular in the form of 50/50 blend t-shirts and poly cotton t-shirts, offer a hybrid fabric that merges the resilience of polyester with the natural comfort of cotton. The feel of these poly blend shirts tends to be smoother and more shape-retentive than pure cotton. Cotton poly blend t-shirts especially are known for their enhanced durability, resisting shrinkage and wrinkling, thus providing a lasting fit and consistent appearance.

In contrast, 100% cotton shirts boast a softness and breathability that is highly sought-after in hot weather. However, pure cotton can be prone to fading, shrinking, and wrinkling over time, which might affect the garment's longevity and crisp look.

From a printing perspective, each fabric has its pros and cons. Screen printing on poly blend shirts can be more challenging due to the fabric's heat sensitivity, which can lead to dye migration. However, polyester blends are excellent for vibrant and crisp designs since they hold color well, making them a favored choice for bold graphics and vivid colors.

DTG printing, on the other hand, works exceptionally well on 100% cotton due to the fabric's natural absorbency, allowing for detailed and complex designs with a softer touch. While DTG can be used on cotton poly blend t-shirts, it requires a pre-treatment to ensure the ink adheres properly and remains vibrant.

Ultimately, the choice between poly cotton shirts, poly blend, and pure cotton will depend on the desired balance of comfort, longevity, and the intended use of the shirt, particularly when it comes to printing methods. While polyester blends offer durability and vibrant prints, 100% cotton remains unmatched in softness and breathability.