Material Deep Dives: How to Choose the Right Fabric for Your Custom Merch
At Nerds, we believe good merch starts with great materials. Whether you're customizing a T-shirt, hoodie, or bag, the fabric you choose affects not just how it looks and feels — but also how long it lasts and how it's perceived. In this guide, we break down the most common materials used in our custom products and help you decide what’s best for your brand.
1. Cotton: The Classic Choice
Cotton is a staple for a reason. It’s breathable, soft, and works great for screen printing and embroidery. But not all cotton is the same.
🌱 Organic Cotton
Used in many of our Stanley/Stella pieces, organic cotton is grown without harmful chemicals. It's better for the planet and feels better on the skin. Great for eco-conscious brands or anyone who wants to highlight sustainability.
🧺 Combed & Ring-Spun Cotton
This process makes the fibers smoother, stronger, and less prone to pilling. It’s what gives shirts like the Creator 2.0 their premium feel and long life.
2. Polyester & Blends: For Performance and Durability
When you need strength, stretch, or specific finishes, polyester enters the chat. It’s ideal for bags, outerwear, or apparel that needs to hold up over time or dry quickly.
🤖 Cotton-Poly Blends
Combining cotton’s softness with polyester’s durability, blends are used in products like the Drummer 2.0 hoodie. They offer the best of both worlds — comfort, color retention, and reduced shrinkage.
♻️ Recycled Polyester (rPET)
Some of our garments and bags use rPET — made from recycled plastic bottles. It’s a smart, sustainable option for clients who want strong material with a light footprint.
3. Heavyweights vs. Lightweights: Fabric Weight Basics
Fabric weight is measured in grams per square meter (gsm). Here's a cheat sheet:
- 160–180gsm: Lightweight, breathable (e.g. Creator 2.0 tee)
- 200–220gsm: Midweight, textured feel (e.g. Sparker 2.0 tee)
- 240–350gsm: Heavyweight, structured and premium (e.g. Freestyler or Slammer 2.0)
Heavier fabrics feel more substantial and are great for oversized or high-end looks. Lighter fabrics are perfect for everyday basics, layering, or hot climates.
4. Special Materials That Make an Impression
Sometimes it’s the texture or origin of the material that makes the product stand out. A few examples from our Nerds range:
- 🌾 Wheat Straw Plastic: Used in our best-selling pen, it’s durable, biodegradable, and has a unique speckled look.
- 🧵 Brushed Cotton Fleece: Found in hoodies like the Cruiser 2.0 — super soft inside for maximum comfort.
- 💼 PU Leather: Used in our duffel and backpack — vegan, premium-looking, and ideal for embossing or hot stamping.
5. Choosing the Right Material for Your Use Case
Different needs = different fabrics. Here’s what we usually recommend at Nerds:
- 🧑💼 Teamwear / Uniforms: Cotton-poly blends for easy care
- 🎁 Giftable Merch: 100% organic cotton or heavyweight cotton for a premium feel
- 🌍 Eco-Friendly Brands: Organic cotton, rPET, wheat straw
- 💪 Outdoor / Activewear: Polyester or tech blends
Materials That Make a Difference
Smart merch isn’t just about logos — it’s about choosing materials that tell your story, reflect your values, and feel great to wear or use. At Nerds, we help you pick the fabric that matches your project, your people, and your purpose.
Not sure which material fits your idea?
