Choosing the Right Fabric for Custom Apparel

When customers touch your apparel for the first time, the fabric is what they notice. It’s not just about how the garment looks—it’s about how it feels, how it holds up after washing, and whether it reflects your brand’s quality. Choosing the right fabric is one of the most important decisions in custom apparel. Get it wrong, and you risk high return rates and bad reviews. Get it right, and your products will become everyday favorites that people recommend.

This guide explores the major factors you need to consider: fabric types, blends, weight, construction, durability, and testing. By the end, you’ll know exactly how to choose fabrics that align with your vision and meet your customers’ needs.

Step 1: Learn about different types of fabric and how they work together.

Cotton, bamboo, and linen are all natural fibers that let air through and feel good. Cotton is the traditional material for T-shirts and hoodies, but bamboo makes them softer and gives them a more eco-friendly look. Linen is light and fashionable, but not as prevalent for mass clothing. Synthetic fibers like polyester and nylon make things last longer and repel dampness. They are great for clothes for sports or the outdoors. Cotton-polyester blends, for example, combine the best of both worlds: comfort and resistance to wrinkles.  Tri-blends (cotton, polyester, rayon/spandex) are becoming more and more popular since they feel soft and modern. 

Step 2: Fabric Weight and Structure

The GSM (grams per square meter) of a fabric tells you how thick and strong it feels. Lightweight fabrics (120–150 GSM) are great for hot weather or when you want to layer. For everyday wear, midweight (160–200 GSM) is the best choice.  Heavyweight fabrics (200+ GSM) are strong and appear high-end, making them great for fashion-forward lines.  In addition to weight, think about the knit structure. For example, jersey knits are elastic and great for T-shirts, while fleece keeps hoodies warm. Canvas and denim are woven textiles that give structure, although they aren't as frequent in casual clothes.

Step 3: Match Fabric to Purpose

Always be sure that the fabric you choose is right for the job:

• Streetwear: Heavyweight cotton or mixes for strength and structure.

• Sportswear: Polyester blends and other synthetics that wick away moisture.

• Basic clothes: Soft cotton or tri-blends for comfort.

• Eco lines: Use organic cotton, recycled polyester, or bamboo to be more environmentally friendly.

• High-end fashion: Textures or finishes that are one of a kind, such slub cotton or brushed fleece.

Step 4: How long it lasts, how to care for it, and what customers expect

To keep customers happy, things need to be durable.  High-quality materials should not pill, shrink, or fade. Think about how the clothes will be laundered; clients like clothes that are easy to care for.  If your target market expects high quality, spending more on better fabric will pay off in terms of reputation and repeat business. Keep in mind that how a piece of clothing feels in your hands might be just as important as how it looks.

Step 5: Test Before Making

Don't ever agree to a big order without trying it first.  Ask for samples and wash them a few times to observe how well they keep their color and form. To see how the fabric behaves, print or embroider your pattern on it. Some textiles soak up ink well, while others make colors fade or blur.  A few team members or consumers can try on the clothes and tell you if they are comfortable and durable before you start making a lot of them.

Common Mistakes to Avoid

One of the most frequent mistakes is using low-resolution artwork. If your design file isn’t sharp enough, the print will look blurry or pixelated. Customers immediately notice when a shirt looks “cheap,” and it usually comes down to poor file preparation. Always supply vector files (like AI or EPS) or at least 300 dpi images to guarantee crisp results.

Another issue is choosing fabric that doesn’t match the purpose. For instance, a heavy cotton shirt might feel great for streetwear but will be too hot for a summer event. On the other hand, a thin, lightweight tee won’t hold up well for work uniforms or sportswear. Matching the weight and fabric blend to the actual use case is critical.

A lot of new designers also make layouts that are too complicated. Tiny details, thin lines, or too many colors often don’t translate well to print. Simple, bold patterns usually have the most effect and are easier to make over and over again.

Lastly, not proofreading before manufacturing is a very expensive mistake. You could end up with prints that are not aligned, colors that are wrong, or sizes that are wrong if you don't look at a sample or mock-up. Taking the time to approve samples makes sure that the final order fits your needs and makes your consumers happy.

Conclusion and Call to Action

Fabric choices define your product’s success. They determine comfort, durability, and customer loyalty. By learning the differences between fabric types, testing samples, and aligning with your audience’s needs, you’ll create garments that people love to wear. Need guidance or swatches for your next line? Contact us today, and we’ll help you choose fabrics that fit your brand vision and budget.