The Science Behind Polyester And Cotton Blend: What Makes It So Special


The type of fabric you choose for your garments will have a direct impact on the final outcome. When it comes to the success or failure of an apparel business or how to start a t-shirt business, the fabric makes all the difference.

All fabrics are unique in their feel and function. Fabric quality, durability, and shrinkage are just as important as the garment’s looks in determining a product’s success or failure.  As a result, the fabric market is flooded with options. However, cotton, polyester, and mixed fabrics are by far the most common.

This article will help you choose the right fabric for your needs by providing information about the differences between polyester and cotton blend.


Polyester And Cotton BlendCotton, a staple fabric that is both soft and fluffy, is farmed in warm climates all over the world.

Cotton is a charming and rich fabric that is soft against the skin. Cotton, among the softest textiles, works well for clothes and other everyday products.

Different varieties of cotton have specific qualities that make them well-suited for particular applications. There are four major categories of cotton:

  • Upland Cotton

Polyester And Cotton BlendMost cotton farmed across the world is upland cotton, which makes up around 90% of the total. It is well-known for its strength, longevity, and adaptability and has a staple length of roughly 1.2 to 1.6 inches. Clothing, home furnishings, and even industrial goods are just some of the many places you can find upland cotton in use.

  • Pima Cotton

Polyester And Cotton BlendPima cotton, also known as extra-long-staple cotton, is a superior kind of cotton renowned for its plushness, durability, and sheen. It is simpler to spin into fine, strong yarns because the staple length is longer than upland cotton, often ranging from 1.5 to 2.5 inches. Most commonly, Pima cotton is seen in high-end clothing and bed linens.

  • Organic Cotton

Polyester And Cotton BlendOrganic cotton is a more sustainable and environmentally friendly alternative to conventional cotton because it is grown without the use of synthetic fertilizers or pesticides. The soil is kept healthy and pests are kept at bay through the use of natural methods like crop rotation and companion planting. Clothing, bedding, and toiletries are just some of the many things that make use of organic cotton.

  • Sea Island Cotton

Polyester And Cotton BlendRare and pricey, Sea Island cotton is an extra-long staple kind grown only in a few places like the West Indies and the United States. With a staple length of 2.5–3 inches, Egyptian cotton is one of the longest and finest cotton fibers are available and prized for their durability, smoothness, and luster. The smoothness and longevity of Sea Island cotton make it ideal for high-end clothing like expensive dress shirts.

  • Acala Cotton

Polyester And Cotton BlendThe southwestern United States is home to the majority of the world’s acreage of the upland cotton variety known as Acala. It is noted for its durability and consistency and has a staple length of between 1.2 and 1.6 inches. Fabrics like denim, towels, and bedding may all benefit from the versatility of Acala cotton.

  • Delta Pine Cotton

Polyester And Cotton BlendThe southern United States is the primary producer of Delta Pine cotton, an upland cotton type. It is recognized for its strength, homogeneity, and high yield, despite its small staple length (usually between 1.2 and 1.4 inches). You may find textiles made from Delta Pine cotton everywhere from clothing and accessories to curtains and upholstery.

  • Xinjiang Cotton

Polyester And Cotton BlendCotton from the Xinjiang region of China is a special type of upland cotton. It is recognized for its strength, suppleness, and moisture absorption, and has a staple length of between 1.2 and 1.6 inches. Clothing, home furnishings, and even industrial goods can all benefit from the versatility of Xinjiang cotton.

  • Dharwad Cotton

Polyester And Cotton BlendThe Indian state of Karnataka is home to the cultivation of upland cotton known as Dharwad. It is well-known for its excellent production and resilience to pests and diseases and has a short staple length, often falling within the range of 1.0 to 1.3 inches. Sarees and dress fabrics are the most common end uses for cotton grown in Dharwad.

  • Levant Cotton

Polyester And Cotton BlendLevant cotton is an upland cotton type that is cultivated in the Eastern Mediterranean countries of Turkey, Syria, and Egypt. Its staple length is between 1.2 and 1.5 inches, making it a strong and long-lasting material. Clothing, home furnishings, and even industrial goods all benefit from the versatility of Levant cotton.

  • Suzhou Cotton

Polyester And Cotton BlendThe Jiangsu province of China is home to the upland cotton known as Suzhou cotton. The staple length of this type of cotton is normally between one and three inches, and it is prized for its softness and ability to absorb dampness. Sheets, towels, and garments are some of the most common applications for Suzhou cotton.

  • Pima Cotton

Polyester And Cotton BlendThe southern United States, Peru, and Australia are the primary producers of Pima cotton, extra-long-staple cotton. Its staple length is between 1.5 and 2 inches, and its strength, durability, and softness are among its many desirable qualities. Pima cotton is used for a variety of textiles, including luxurious towels, clothing, and sheets.

  • Egyptian Cotton

Polyester And Cotton BlendEgypt is the primary source country for the extra-long staple cotton known as Egyptian cotton. The staple length is between 1.5 and 2 inches and it is durable, silky, and shiny. Luxury clothing, towels, and bed linens are just some of the many places you may find textiles made from Egyptian cotton.

  • Supima Cotton 

Polyester And Cotton BlendSupima cotton is an exclusive trademarked breed of long-staple cotton grown in the United States. The 1.5–2 inch staple length of this fiber gives it the strength, suppleness, and durability for which it is recognized. High-quality bed sheets, towels, and clothing are just some of the many textiles uses for Supima cotton.

The world is home to a wide variety of cotton varieties. Because different varieties of cotton have varied qualities and traits, they can be used in various contexts and sold in various marketplaces.

The following characteristics of cotton 

  • Staple length
  • Strength
  • Softness
  • Moisture absorption 

In addition to the final use of the textile, determine which variety of cotton is optimal.

  • Cotton Fabric With Printed Designs

Polyester And Cotton BlendCustomers tend to favor cotton t-shirt materials since they print so well. Fabrics made of cotton respond particularly well to screen printing using water-based inks. 

You can also print on cotton with DTG. 

The best results are achieved when printing on 100% cotton. T-shirts made from cotton are often inexpensive. 


Polyester is a long-lasting fabric that won’t soak up much water. This speeds up the drying time for the tees. The material is also extremely durable, so it won’t easily stretch or shrink.

  • Athletic Activity

Polyester And Cotton Blend

Those who enjoy physical activity or the outdoors will find this to be a fantastic choice. Polyester’s odor-resistant properties come in handy in sweaty situations. The fabric’s low absorbency contributes to how quickly it dries. 

This is a wonderful trait to have if you plan on spending a lot of time in the great outdoors. It can help you avoid overheating and keep dry in humid climates.

  • Fewer Stains

Polyester And Cotton BlendT shirt manufacturers of polyester are less likely to be stained as a result. T-shirts made from this material shouldn’t become stained as easily as those made from more absorbent materials.

  • Durable Fabric

Polyester And Cotton BlendThe durable fibers prevent the t-shirt from deteriorating quickly. Additionally, the fabric is less likely to shrink. It will retain its color and durability even after several washes and wears. It will also keep its reputation as a comfortable t-shirt material. 

There are many different variants of polyester, but these are the most common. The qualities and performance requirements of a certain application will determine which type of polyester is utilized.

  • Polyethylene Terephthalate (PET)

PET is the most widely used kind of polyester and can be found in many different products, such as food packaging, clothing, and building supplies. It can withstand exposure to both water and chemicals while still being incredibly lightweight and robust. PET is widely utilized for bottle and container production because of its versatility and ease of recycling.

  • Polybutylene Terephthalate (PBT)

PBT is a form of polyester widely used in a wide variety of applications, from automobiles and electronics to home goods and recreational goods. It is a durable and malleable substance that can withstand extreme heat and a wide variety of chemicals.

  • Polyethylene Naphthalate (PEN)

In the manufacturing of advanced materials like films and fibers, PEN polyester is often used. It is highly resistant to wear and tear and has a high breaking strength. Heat, chemicals, and water are no match for PEN’s durability.

  • Polytrimethylene Terephthalate (PTT)

PTT polyester is a relatively new material with promising prospects in the textile sector. It’s a greener option since it can be made with less energy and fewer harmful byproducts than conventional polyester. PTT fibers are employed in a wide range of textile applications due to their high stretch and recovery qualities.

  • Polycarbonate (PC)

Among the many uses for the polyester known as polycarbonate are those in the fields of electronics, automobiles, and medicine. It is resistant to both high temperatures and impacts, and it is both lightweight and translucent. Polycarbonate is not only long-lasting, but also impervious to corrosion, solvents, and ultraviolet light.

  • Polypropylene (PP)

Thermoplastic polymer polypropylene is frequently used in place of polyester in places like packaging, textiles, and automobile components. It’s a sturdy yet lightweight textile that holds up well against water and chemicals. Polypropylene is widely utilized because it is inexpensive, durable, and recyclable.

Printing On Polyester

Polyester And Cotton BlendPolyester fabrics are ideal for heat transfer printing. This process involves making a design on a computer and printing it out on self-adhesive vinyl. Heating the pattern causes it to transfer to the fabric.

This printing method is extremely versatile because it may be used with a wide variety of substrates. The plastic material of the transfers makes them suitable only for synthetic materials.

Sublimation printing also works well on polyester. Polyester is commonly low-priced as well. It varies in cost from one vendor to the next. Additionally, the price is typically lower than that of cotton.

Blended Fabrics 

Polyester And Cotton BlendFabrics that contain a blend of fibers are manufactured by blending two or more fabric types. Simply put, yarn is made by twisting together several fibers. You can choose from a variety of fiber types for these purposes, each with its own set of benefits. 

  • Performance 
  • Cost
  • Aesthetics
  • Composition   
  • Length
  • Thickness 
  • Color

Moreover, the following are all examples of blending techniques.

  • Bale mixing 
  • Flock blending
  • Web blending 
  • Sliver blending 
  • Fiber blending
  • Roving blending 

A fabric that is a combination of cotton and polyester fabric benefits from the best qualities of both fibers. Clothing made from poly cotton is lightweight, durable, and comfortable. It may also be made into abrasion-resistant materials like canvas. Poly-cotton blends are not as cheap as pure polyester, but they are less expensive than 100% cotton and more comfortable. 

Because of its low cost, long lifespan, and wide range of available colors, the 65/35 cotton and polyester blend fabric is the go-to for most workplace uniforms. Whether you should get 100% cotton or a poly-cotton blend for your work clothes is mostly a matter of personal preference and the conditions under which you’ll be working. Workers who spend their days inside near machines may benefit from polyester and cotton fabric durability. It may be preferable to use a cloth that is 100% cotton if the work is to be done outside, especially in hotter areas. 

Fabrics’ overall performance and qualities, like their durability, breathability, and moisture-wicking abilities, can be enhanced by blending fibers. The most popular mixed fabrics include the following:

  • Polyester/Cotton (Polycotton)

Polyester And Cotton BlendPolycotton is a common cotton and polyester blend fabric that combines the comfort and breathability of cotton with the resilience and resistance to wrinkles that polyester provides. It finds widespread application in textiles and textile-related products.

  • Rayon/Polyester

Polyester And Cotton BlendClothing and home goods made from rayon and polyester blends are commonplace. The fabric is comfortable and long-lasting because rayon’s softness and breathability are combined with polyester’s strength and durability.

  • Cotton/Linen

Polyester And Cotton BlendBlends of cotton and linen are frequently used during the warmer months. Breathable and pleasant in warm weather, this fabric is a blend of the softness of cotton and the natural texture and drape of linen.

  • Wool/Polyester

Polyester And Cotton BlendSuits and other dress clothes often use polyester blended fabric with wool. This fabric is warm and long-lasting because wool’s natural insulating capabilities are combined with polyester’s strength and durability.

  • Silk/Cotton

Polyester And Cotton BlendLuxury apparel and household goods frequently feature silk/cotton blends. Luxurious and functional, this fabric is the result of blending silk’s natural sheen and softness with cotton blend vs cotton breathability and durability.

  • Acrylic/Wool

Polyester And Cotton BlendWinter apparel and accessories frequently feature acrylic/wool blends. Warmth, lightness, and simplicity of care are the result of blending the insulating attributes of wool with the smoothness and durability of acrylic.

  • Nylon/Spandex

Polyester And Cotton BlendAthletic wear and other forms of stretchy apparel frequently employ nylon/spandex blends. The elastic properties of spandex combined with the strength and durability of nylon create a fabric that is both soft and versatile.

  • Cotton/Polyester/Rayon

Polyester And Cotton BlendAddition of rayon in polyester and cotton blend, often referred to as “tri-blend,” this fabric combines the best qualities of cotton, polyester, and rayon. T-shirts and sweatshirts are common places to find this material.

  • Wool/Cashmere

Polyester And Cotton BlendSuits and coats are examples of high-end apparel that benefit from wool and cashmere blends. Warmth and comfort are achieved by combining the insulating properties of wool with the softness and luxuriousness of cashmere.

  • Nylon/Polyester

Polyester And Cotton BlendJackets and backpacks made from nylon/polyester blends are common pieces of outdoor equipment. Nylon’s strength and durability, combined with polyester-blend resistance to water, results in a fabric that is both robust and weatherproof.

  • Polyester/Bamboo

Polyester And Cotton BlendThere has been a recent uptick in the use of fabrics made from polyester blend fabric with bamboo. The fabric is durable and comfortable thanks to the blend of polyester, known for its longevity, and bamboo, known for its softness and natural moisture-wicking capabilities.

There are countless varieties of blended fabrics, and these are just a handful. How the fibers are put together will depend on what qualities and functions the fabric needs to have.

Printing On Blended Fabrics

Polyester And Cotton BlendThese mixes are usually very strong as screen print vs sublimation don’t really work on them, so they are great for embroidery. The stronger the cloth, the better the chance it will work. If the fabric has a tight and secure weave, it should be able to withstand the needles.
The price of blends is somewhere between what cotton vs cotton-poly blend costs. Polyester costs more than cotton, which is very cheap. Combining the two makes the final product cheaper than if it were all cotton.

Which Percentage Of Cotton Polyester Blend Works Best?

Although the ratio fluctuates, the most frequently used combination is 65% cotton and 35% polyester. You may also readily find 50/50 mixes in stores. Knowing the basic characteristics of cotton and polyester will help you determine the ideal blend %. 

In terms of fibers, cotton is unrivaled. It’s soft and gentle on the skin, and it feels great on it. The addition of cotton polyester material results in a fabric that is both inexpensive and long-lasting. 

Many other percentages of a cotton poly blend fabric used are

  • 80%/20% 
  • 65%/35%
  • 50%/50%
  • 35%/65%

The blended fabrics with a higher percentage of cotton will be the safest bet. Fabrics are chosen for a wide variety of reasons, including current trends, practicality, longevity, industry needs, and so on. Fabric choices should be made with both your needs and your budget in mind.

The list is as follows:

  • Fabric with a composition of 20% cotton and 80% polyester is ideal for a strong, lightweight, elastic material.
  • 50% Cotton and 50% polyester is for durability, hypoallergenic, moisture absorption, breathability, and softness.
  • Material of 60% or 65% cotton and 40% or 35% polyester is low-strength, hypoallergenic, very perspiration-absorbent, and highly breathable.



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