Best Fabrics for Screen Printing: Cotton vs. Polyester vs. Blends

Screen printing has the power to transform ordinary fabrics into stunning, wearable masterpieces. Whether you’re a small business owner launching a custom t-shirt brand, an artist looking to bring your designs to life, or a hobbyist experimenting with DIY apparel, selecting the right fabric is crucial to achieving a high-quality print. The fabric you choose affects not only the vibrancy of your design but also the durability, texture, and overall feel of the final product.

In Australia, where climate conditions range from scorching summers to cooler winters, the choice of fabric becomes even more important. Lightweight, breathable materials like cotton are ideal for warm weather, while blends with polyester offer durability and moisture-wicking properties—perfect for activewear. Additionally, sustainable fabric options such as organic cotton and bamboo are gaining popularity, aligning with the growing demand for eco-friendly fashion.

From classic cotton tees to performance fabrics and eco-conscious alternatives, In this article, let’s explore the best printable fabrics through an Australian lens, helping you find the perfect canvas for your next screen printing project.

Understanding the Basics: Why Fabric Choice Matters

Before exploring specific materials for screen printing, it’s essential to understand why fabric selection plays a vital role in screen printing success. The fabric you choose impacts several key factors, including:

• Print Quality and Durability – A smooth, high-quality fabric ensures crisp, long-lasting prints, while rough or uneven materials can lead to fading, cracking, or inconsistent designs.
• Colour Vibrancy and Appearance – Different fabrics absorb ink differently. Natural fibres like cotton hold ink well, while synthetic blends may require special inks to achieve vibrant colours.
• Comfort and Wearability – Australia’s climate varies from humid summers to cooler winters, making fabric breathability, softness, and flexibility important considerations.
• Production Costs – Some fabrics are more affordable and easier to work with, while others require specialized inks or pre-treatments, adding to the overall cost.
• Environmental Impact – With growing awareness of sustainable fashion, many Australian brands are opting for organic cotton, hemp, or recycled materials to reduce their environmental footprint.

As experienced Australian screen printing brand Permaset highlights: “The fabric is the foundation of every screen printed garment – choose carefully and your prints will shine.” By selecting the right fabric, you can ensure your designs not only look great but also stand the test of time.

Cotton: The Classic Choice

Cotton has been the gold standard for screen printing in Australia for decades, and for good reason. This natural fibre absorbs ink effectively, resulting in bold, vibrant prints with excellent detail and durability. Its smooth and even surface allows for crisp lines and high-definition designs, making it a favourite among both beginners and professional printers.

Beyond print quality, cotton is soft, breathable, and comfortable, making it ideal for the Australian climate. Whether you’re printing on lightweight cotton for summer t-shirts or heavier cotton for hoodies and tote bags, this fabric ensures a great balance of comfort and wearability. Additionally, cotton’s versatility makes it suitable for a wide range of applications, from fashion and merchandise to promotional apparel.

For those looking for an eco-friendly option, organic cotton is an excellent choice. It offers the same high-quality printing results while reducing environmental impact by eliminating harmful pesticides and chemicals from the production process.

From classic tees to trendy streetwear, cotton remains a reliable and timeless choice for screen printing projects.

Advantages of Cotton

• Superior Ink Absorption – Cotton fibres naturally soak up both water-based and plastisol inks, allowing for vibrant, opaque, and long-lasting prints.
• Breathability – Cotton’s lightweight and airy nature makes it perfect for Australia’s hot summers, keeping wearers cool and comfortable.
• Soft Hand Feel – Provides a smooth, comfortable base that feels gentle against the skin, making it a favourite for casual and everyday wear.
• Sustainability Factor – As a biodegradable and renewable natural fibre, cotton is a more eco-friendly choice compared to synthetic materials. Many brands now opt for organic cotton to further reduce environmental impact.

Disadvantages of Cotton

• Shrinkage – Cotton can shrink significantly after washing if it hasn’t been pre-shrunk or properly cared for.
• Wrinkles Easily – Compared to synthetic fabrics, cotton requires more maintenance to keep a neat and polished appearance.
• Longer Drying Time – Cotton retains moisture longer than synthetics, making it less ideal for activewear, especially in humid Australian conditions.

Despite these drawbacks, cotton remains a top choice for screen printing, offering unmatched print quality, comfort, and versatility for a wide range of apparel and textile projects.

Best Uses for Cotton

Cotton is the go-to fabric for high-quality retail t-shirts, merchandise, and fashion items where both comfort and print quality matter. Its ability to hold vibrant, detailed prints makes it perfect for:

• Branded apparel – Ideal for businesses looking to create stylish, professional-quality merchandise.
• Streetwear and fashion – Used by independent designers and major brands alike for its soft feel and premium look.
• Event and promotional t-shirts – A popular choice for concerts, festivals, and corporate giveaways due to its durability and comfortable wear.
• Ethical and eco-conscious brands – With sustainable cotton options available, many Australian brands opt for organic cotton to align with environmentally friendly values.

Companies like AS Colour, a favourite among Australian screen printers, offer high-quality cotton blanks known for their exceptional printability, durability, and comfort. Their premium cotton garments have set an industry standard, making them a top choice for businesses and creatives looking to produce professional-grade screen-printed apparel.

Polyester: The Performance Powerhouse

Once considered challenging for screen printing due to dye migration issues, polyester has undergone significant advancements, making it a go-to fabric for performance wear. With the rise of Australia’s active outdoor lifestyle, demand for moisture-wicking, durable, and lightweight apparel has skyrocketed—pushing polyester to the forefront of screen printing materials.

Modern low-bleed and dye-blocking inks have revolutionized polyester printing, allowing for sharp, vibrant designs without colour distortion. This makes polyester an excellent choice for sportswear, uniforms, and athleisure, where both functionality and branding are key. Whether it’s for gym gear, marathon shirts, or surf wear, polyester has become a printing staple in Australia’s booming fitness and outdoor industries.

Advantages of Polyester

• Moisture-Wicking Properties – Polyester efficiently draws sweat away from the body, keeping wearers cool and dry, making it essential for Australia’s warm and humid climate.
• Durability – Highly resistant to stretching, shrinking, and wrinkling, polyester holds its shape even after multiple washes, making it ideal for long-lasting apparel.
• Quick-Drying – Unlike cotton, polyester dries rapidly, making it perfect for athletic wear, swimwear, and outdoor gear, especially in Australia’s beach and sports culture.
• UV Resistance – Many Australian-made polyester garments come with built-in UV protection, making them a smart choice for outdoor workers, athletes, and beachgoers.

Disadvantages of Polyester

• Dye Migration Challenges – Polyester requires special low-bleed inks and curing techniques to prevent colour distortion and maintain print clarity.
• Less Breathable – Compared to cotton, polyester traps more heat, which can feel uncomfortable during extreme summer temperatures.
• Environmental Concerns – As a synthetic fabric, polyester is not biodegradable and contributes to microplastic pollution, making sustainability-conscious brands seek recycled polyester alternatives.

Despite its drawbacks, polyester remains a top performer in sportswear, uniforms, and activewear, offering durability, moisture control, and UV protection—key factors in Australia’s outdoor and fitness-driven culture.

Best Uses for Polyester

Polyester is the go-to fabric for athletic wear, team uniforms, and outdoor apparel, thanks to its durability, moisture-wicking properties, and quick-drying nature. It’s particularly well-suited for:

• Sports and Activewear – Gym shirts, running tops, and cycling jerseys that need to keep athletes cool, dry, and comfortable.
• Team Uniforms – Widely used for football, cricket, and netball jerseys due to its resistance to stretching and fading.
• Outdoor Workwear – Ideal for tradies, lifeguards, and event staff needing UV protection and durability under Australia’s harsh sun.
• Beach and Swimwear – Quick-drying properties make polyester perfect for boardshorts, rash vests, and surfwear.

Australian suppliers like BizCollection and Winning Spirit have developed specialized polyester fabrics engineered to accept screen printing inks while maintaining high-performance properties. Their premium blends ensure bold, long-lasting prints without compromising the breathability, stretch, and moisture control needed for Australia’s demanding outdoor conditions.

Poly-Cotton Blends: The Best of Both Worlds

Poly-cotton blends, often 50% cotton and 50% polyester, offer a versatile alternative to pure cotton or polyester, with ratios varying depending on the intended use. By combining cotton’s softness and breathability with polyester’s durability and moisture resistance, these blends create an ideal printing surface that works well across Australia’s diverse climate zones.

From humid coastal cities to dry inland regions, poly-cotton fabrics provide a comfortable, lightweight feel while maintaining enhanced durability—making them a popular choice for screen printing across multiple industries.

Advantages of Blends

• Reduced Shrinkage – The polyester content helps maintain shape and size even after multiple washes, making it ideal for Australia’s frequent washing cycles.
• Good Ink Absorption – The cotton component allows for strong, vibrant prints that hold up well under the harsh Australian sun.
• Comfort with Performance – Blends offer a balanced mix of breathability, softness, and moisture control, making them a versatile choice for year-round wear.
• Cost-Effective – Often more affordable than 100% cotton, making them a budget-friendly option for businesses and brands in Australia’s competitive market.

Disadvantages of Blends

• Potential Pilling – Some blends may develop small fibre balls over time, especially with heavy use or friction.
• Middle-Ground Approach – While blends combine the benefits of cotton and polyester, they don’t fully match the superior comfort of cotton or the high-performance features of polyester.

Despite these minor drawbacks, poly-cotton blends remain a favourite for screen printing, offering durability, affordability, and print quality—making them an excellent choice for Australian brands looking for a versatile and cost-effective fabric.

Best Uses for Blends

Poly-cotton blends are versatile workhorses, making them a top choice for:

• Promotional T-Shirts – Ideal for events, giveaways, and branded merchandise, offering a balance of affordability, comfort, and durability.
• Work Uniforms – Perfect for tradies, hospitality staff, and corporate uniforms, as they hold up well to frequent washing and wear.
• Casual and Everyday Wear – Blends provide a soft feel with added durability, making them great for streetwear, retail apparel, and lifestyle brands.

Companies like Gildan Australia and JB’s Wear offer premium blends that have become industry standards, valued for their quality, affordability, and reliable printability in the Australian market.

Specialty Fabrics Worth Considering

There are other specialty fabrics that you can consider for screen printing. I have provided the complete list below.

Bamboo Blends

As sustainability becomes a key focus in Australia’s fashion and textile industry, bamboo blends are gaining popularity for their eco-friendly properties and luxurious softness.

• Ultra-Soft Feel – Bamboo fabric is naturally silky, providing a high-end, comfortable wear.
• Eco-Friendly & Sustainable – Bamboo grows rapidly without pesticides and requires less water than cotton, making it a great choice for environmentally conscious brands.
• Breathability & Moisture Control – Naturally moisture-wicking and antibacterial, bamboo blends keep wearers cool and fresh, making them ideal for Australia’s warm climate.
• Good Printability – While slightly more delicate than cotton, bamboo blends can still hold ink well, especially with water-based inks.

Ethical Clothing Australia-certified suppliers like Bamboo Textiles Australia offer several bamboo fabric options tailored for screen printing, providing sustainability without compromising quality.

Hemp

Hemp is another sustainable powerhouse making waves in Australia’s eco-conscious market. Known for its durability and low environmental impact, hemp fabrics are an excellent alternative for brands seeking sustainable yet long-lasting materials.

Why Choose Hemp for Screen Printing?

• Exceptional Durability – Hemp fibres are stronger than cotton, meaning garments last longer and resist wear and tear.
• Eco-Friendly – Requires less water, fewer pesticides, and regenerates soil, making it one of the most sustainable fabric choices.
• Breathable & UV-Resistant – Naturally moisture-wicking and resistant to UV rays, making it perfect for Australia’s sunny climate.
• Unique Texture & Printability – Hemp’s slightly textured surface gives prints a natural, earthy aesthetic, which suits organic, eco-conscious brands.

Australian companies like Hemp Clothing Australia specialize in high-quality hemp blends designed for screen printing, offering a durable, environmentally friendly canvas for sustainable fashion and merchandise.

Australian Merino Wool

A premium, locally sourced option, Australian Merino wool offers a high-end, natural alternative for screen printing. While traditionally associated with knitwear and luxury fashion, advancements in printing techniques now allow for high-quality screen prints on Merino wool garments.

Why Use Merino Wool for Screen Printing?

• Unmatched Softness – Finer than regular wool, Merino offers a luxuriously soft, non-itchy feel.
• Temperature Regulation – Naturally breathable and moisture-wicking, keeping wearers cool in summer and warm in winter—ideal for Australia’s varied climate.
• Odour-Resistant & Antibacterial – Merino’s natural properties prevent odour buildup, making it perfect for activewear and premium casualwear.
• Sustainably Sourced – As an Australian-grown natural fibre, Merino is renewable, biodegradable, and ethically farmed.

Best Uses for Merino Wool in Screen Printing

• Luxury fashion & premium streetwear
• High-performance activewear & outdoor apparel
• Sustainable & ethical clothing brands

Suppliers like The Woolmark Company offer printable Merino wool options, allowing Australian brands to showcase the country’s world-class wool industry while creating high-end, breathable garments with unique screen-printed designs.

Making Your Decision: Practical Considerations

Before making any decision it is very important to take these points into consideration.

Budget Realities

• Cotton – While basic cotton garments are reasonably priced, premium options like Australian-grown cotton or organic cotton can be more expensive due to their higher quality and sustainability credentials.
• Polyester – Generally more affordable, especially for bulk orders, making it a cost-effective choice for sportswear, uniforms, and promotional merchandise.
• Blends – Offer the best balance of cost, durability, and print quality, making them a top choice for Australian businesses looking for value without compromising performance.

Choosing the right fabric depends on your budget, target market, and intended use, ensuring your screen-printed garments meet both quality expectations and cost considerations.

Print Technique Compatibility

Different screen printing methods work best with specific fabrics. Understanding these relationships ensures optimal print quality and longevity, especially in Australia’s harsh climate.

• Plastisol Inks – A versatile choice that works on all fabrics, but may crack over time on stretchy materials like polyester blends.
• Water-Based Inks – Ideal for high-cotton-content garments, producing soft, breathable prints. These inks are becoming increasingly popular in Australia due to their eco-friendly properties.
• Discharge Printing – Best suited for 100% cotton, as it removes dye from the fabric, creating a super-soft, vintage-style print.
• DTG (Direct to Garment) Printing – Requires a high cotton content (typically 80% or more) for sharp, detailed prints with vibrant colours.

As Australian screen printing supplier Permaset highlights:
“Understanding the relationship between your ink system and fabric is critical to producing prints that last through Australia’s harsh conditions.”

Choosing the right fabric-ink combination ensures long-lasting, high-quality prints that stand up to Australia’s sun, heat, and frequent washing cycles.

Real-World Applications: Finding Your Perfect Match

Every fibre has a different appeal and ideal real-world applications.

For Retail Quality Apparel Brands

For premium retail products, fabric choice plays a huge role in perceived quality and customer satisfaction.

• 100% Combed and Ringspun Cotton – This fabric offers a smooth, high-quality surface for detailed, soft-hand prints that look and feel premium.
• Best for: Streetwear, fashion labels, and high-end merchandise.
• Top Australian Suppliers:
  • AS Colour (ascolour.com.au) – A go-to for fashion-forward, high-quality cotton garments.
  • Blank Clothing (blankclothing.com.au) – Offers affordable premium blanks for retail and custom printing.

Australian customers are willing to pay more for high-quality, well-printed garments, making premium cotton a top choice for brands looking to establish credibility and longevity in the apparel market.

For Athletic and Team Wear

For sportswear and team apparel, performance polyester is the top choice due to its moisture-wicking, durability, and quick-drying properties—essential for Australia’s active, outdoor lifestyle.

• Performance Polyester – Designed to keep athletes cool and dry, while resisting stretching, shrinking, and fading.
• Best for: Sports teams, gym apparel, outdoor gear, and activewear brands.
• Top Australian Suppliers:
  • BLK (blksport.com) – Specializes in custom teamwear and high-performance fabrics for rugby, AFL, and other sports.
  • 2XU – A global leader in technical sportswear, offering elite moisture-wicking and compression gear.

Pairing polyester fabrics with specialized printing techniques, such as sublimation or low-bleed inks, ensures long-lasting, vibrant prints that can withstand intense training and competition in Australia’s demanding conditions.

For Promotional and Event Merchandise

For branded giveaways, corporate events, and bulk promotional apparel, poly-cotton blends offer the ideal balance of affordability, durability, and printability—a key consideration for Australian businesses managing tight budgets.

• Poly-Cotton Blends – Provide good ink absorption, reduced shrinkage, and a comfortable feel, making them a cost-effective yet high-quality option.
• Best for: Trade shows, corporate events, promotional giveaways, and branded merchandise.
• Top Australian Suppliers:
  • JB’s Wear (jbswear.com.au) – A trusted supplier known for durable, budget-friendly apparel ideal for large-scale promotional orders.
  • The Uniform Edit – Specializes in custom-branded corporate and promotional wear, offering versatile poly-cotton options.

By choosing poly-cotton blends, businesses can maximize brand exposure while keeping costs in check, ensuring high-quality promotional apparel that leaves a lasting impression without breaking the budget.

The Future of Printable Fabrics in Australia

As sustainability becomes a major focus in the fashion and printing industries, Australian businesses are embracing eco-friendly fabrics without compromising on print quality and durability.

• Recycled Polyester – Made from reclaimed plastic bottles, reducing landfill waste while maintaining performance benefits.
• Organic Cotton – Free from harmful pesticides and chemicals, offering a softer feel and a reduced environmental footprint.
• Innovative Sustainable Blends – Combining natural fibres like hemp and bamboo with recycled materials for a greener alternative to traditional fabrics.

Leading Australian Brands Driving Change:

• Vege Threads – Specializes in ethical and sustainable fashion, using organic and responsibly sourced materials.
• Etiko – A pioneer in eco-friendly apparel, offering Fair Trade and organic cotton options that are ideal for screen printing.

With Australian consumers increasingly valuing sustainability, businesses that invest in eco-friendly printable fabrics are likely to stand out in the market, aligning with changing consumer expectations and environmental responsibilities.

Final Thoughts: Choosing for Australia’s Unique Conditions

The “best” fabric for screen printing depends on several factors, including your budget, target audience, intended use, and Australia’s unique environmental conditions. Each fabric type offers distinct benefits:

• Cotton provides exceptional print quality and comfort, making it ideal for premium retail apparel.
• Polyester excels in performance wear, offering moisture-wicking properties suited for Australia’s active lifestyle.
• Blends strike a balance between cost, durability, and comfort, making them perfect for promotional and everyday wear.
• Sustainable options like organic cotton, bamboo, and recycled polyester are gaining traction as eco-conscious printing becomes more important.

The Role of Experimentation & Supplier Partnerships

Screen printing is an evolving craft, and testing different fabrics can help achieve the best results. Many successful Australian printers maintain close relationships with suppliers like:

• VistaPrint Australia – A go-to for custom apparel printing.
• Spotlight – A versatile fabric retailer offering various textiles for DIY screen printers.

The Creative Potential of Screen Printing

Regardless of the fabric you choose, screen printing offers endless creative possibilities, allowing you to transform simple textiles into wearable art. With the right materials and techniques, your prints can withstand Australia’s demanding climate while delivering lasting impact and style.