Cotton or Polyester Polo Shirts: The Definitive 2025 Guide for Corporate Buyers

If you’ve ever tried ordering custom-branded polo shirts for your business, you’ve probably run into the age-old question — should you choose cotton or polyester? Our account managers get asked this question weekly from Australian organisations. Both fabrics have their strengths. Both can look fantastic with your logo. But each one performs differently in real-world settings, and knowing the difference will save you complaints from your staff or guests. (and a few sweaty days in the wrong shirt). Let’s take a closer look at the fabrics, their behaviour, and what they mean for your brand.

A Quick Side-by-Side Snapshot

 

 

 

Why Cotton Still Wins Hearts

There’s a reason cotton polos never go out of style. They’re made from a natural fibre that’s soft, breathable, and instantly comfortable. In air-conditioned offices, retail spaces, or conference venues, cotton feels relaxed but still looks professional.

Cotton also lends itself well to screen printing, DTG printing, and embroidery. Colours look bold and crisp, and the material holds its shape under fine stitching — perfect for intricate logos or subtle branding.

However, cotton does require a bit of extra care. It can shrink, crease, or fade after repeated washing; for organisations that need easy-care uniforms or outdoor gear, that can be a limitation.

“Our clients in finance and consulting love cotton polos,” notes one of our apparel specialists. “They’re breathable, classic, and feel premium — exactly the image those sectors want to project.”

Why Polyester Is the Modern Workhorse

If cotton is the classic, polyester is the performer. It’s the material of choice for businesses that need polos to work as hard as their teams do. Polyester fabrics are rugged, lightweight, and built to last. They resist stretching, fading, and wrinkles — even after heavy use and frequent washing.

 

But the biggest reason companies choose polyester? Moisture management. The fabric wicks sweat away from the body and dries fast. In fact when you wash the garment, you will realise it will dry very quickly compared to cotton. It makes it ideal for outdoor staff, event crews, and active environments.

Polyester also pairs perfectly with sublimation printing, allowing full-colour, photo-quality designs that won’t crack or peel. This makes it a favourite for branded sportswear, hospitality teams, and promotional giveaways that need maximum visual impact.

 

“Polyester polos are a lifesaver for our Queensland and WA clients,” says one of our production leads. “They stay cool and dry, even when you’re working outdoors in the middle of summer.”

Of course, the trade-off is texture. Polyester can feel less natural against the skin and, in dry climates, can generate static electricity. But for sheer performance, it’s hard to beat.

The Middle Ground: Poly-Cotton Blends

When you can’t decide between the two, a poly-cotton blend might be the perfect compromise.

These shirts combine the best traits of both fabrics — usually around 60% cotton for comfort and 40% polyester for strength.

Blends are softer than pure polyester yet easier to maintain than cotton, offering a balanced, all-round option for everyday uniforms. They resist wrinkles, hold their colour, and handle branding methods like embroidery, screen printing, and sublimation on treated surfaces with ease.

The downside? They can retain a little more heat than cotton and sometimes develop light fabric pilling over time. However, for teams that need to look professional every day — from warehouse crews to sales staff — blended polos strike the perfect balance.

“Most of our national clients choose blended polos,” says a member of our Sydney sales team. “They look neat, wash easily, and keep their shape. It’s the practical choice for multi-site organisations.”

Branding Matters: Matching Fabric to Decoration

Different fabrics behave differently when decorated. Here’s a simple guide:

 

 

 

Sublimation technology has advanced to the point where even specific cotton-coated blends can now handle it. That means you no longer have to choose between comfort and creativity — you can have both.

Choosing the Right Fabric for Your Workplace

When we look at patterns across our own clientele, the trends are clear:

• Cotton polos are the best choice for office staff, conferences, and client-facing roles. They’re breathable, refined, and comfortable for all-day wear.
• Polyester polos are preferred for outdoor work, logistics teams, or active roles, especially in warmer climates like QLD and WA.
• Poly-cotton blends are the go-to choice for uniform programs and nationwide rollouts, offering a dependable middle ground that suits nearly everyone.

Every industry has its nuance. A tech startup might want breathable cotton for comfort, while a sporting club needs polyester for performance. The beauty of modern polo is that you can have both — often within the same collection.

Cubic Promote’s Take

After years of supplying uniforms to businesses across Australia, one thing we’ve learned is that no fabric fits everyone. What matters most is matching your shirt’s function to your environment.

If your team spends most of the day indoors, go for cotton.

If they’re constantly on the move or outdoors, choose polyester.

If you need versatility and minimal fuss, poly-cotton blends are the best investment.

Whatever you pick, you can count on our team to help you find the right balance between comfort, branding, and longevity.

Ready to Create Your Custom Polo Shirts?

Explore our collection of custom-branded polo shirts or call 1300 858 288 to chat with our apparel team. We’ll guide you through fabric options, branding methods, and production timelines — so your next order looks as good as it feels.