Brushed Cotton vs. Cotton Twill: What is the Difference
By: Melody Posted on: Jul 3, 2025This detailed comparison guide explores the fundamental differences between brushed cotton and cotton twill, two dominant fabrics in the headwear industry. Understanding these materials is crucial for anyone purchasing hats in bulk or seeking the perfect fabric for custom headwear projects.
The fabric composition is arguably the most crucial consideration when buying hats online in bulk. At physical stores, you can get the feel of the fabric before buying hats, but the stores may not stock enough of the styles in sizes and colors you want. Generally, wholesale headwear sources offer all the vital information you would want to know before you make your purchase, including images of the headwear in various colors, details about its customizability, and the hat’s features and fabric materials.
Cotton fabrics dominate the headwear market, offering breathability, comfort, and versatility in decoration. But within cotton's family tree, two fabric materials typically take the spotlight and often confuse buyers: brushed cotton and cotton twill. These fabrics each bring distinct advantages to the table.
Let's dive into what separates them and help you choose the right material for your next cap order.
What is brushed cotton?
Brushed cotton is the result of cotton undergoing a finishing process where metal brushes sweep across the fabric’s surface. This “brushing” removes lint and gives the fabric a soft texture, its signature. The cotton fibers are raised as a result, producing a slightly fuzzy surface that feels amazingly smooth against skin. This also explains why brushed cotton is more preferable than standard cotton. This is premium material that wearers instantly notice.
The Pros & Cons of Brushed Cotton
Pros:
- Much softer than cotton.
- The raised fibers trap air, offering better warmth.
- Despite its warmth, it’s still breathable cotton with good air circulation.
- Smooth, soft surface offering great results for screen printing and embroidery.
- Generally, simple to wash and maintain.
Cons:
- The soft fibers can sometimes form tiny balls (pills) over time.
- Like many cottons, brushed cotton may also shrink if not cared for properly.
- Generally costs more than standard cotton options
How to Customize Brushed Cotton Caps
Brushed cotton is excellent for embroidery and patches due to its soft, stable surface. The raised fibers provide excellent thread grip. Screen printing works well, too, though it requires careful temperature control to prevent fiber damage. Heat transfer vinyl applications need lower temperatures and shorter press times than standard cotton.
What is brushed cotton used for?
Due to its inherent comfort, brushed cotton caps work well for almost everything—from promotions to daily use and uniforming. The premium feel and tactile experience make it a preferred fabric among fashion-forward brands and boutique fashion outlets.
What is cotton twill?
It’s all about the weave in this material. Cotton twill, if you look closely, has a diagonal weave pattern on the surface of the fabric. This is because the fabric is created by weaving parallel diagonal ribs, different from regular cotton, which has a plain weave structure. But it isn’t just the unique looks on the surface level. This weave pattern makes the hat considerably more durable and rigid compared to standard cotton fabrics.
The Pros & Cons of Cotton Twill
Pros:
- Very durable and tear-resistant
- Texture masks stains, dirt, and even minor wrinkles
- Helps the cap hold its shape
- Resists wrinkles to a notable degree
- Suitable for year-round wear
Cons:
- It can feel heavier compared to other cotton fabrics
- Generally costs more than standard cotton options
- Less soft than brushed cotton
- Can feel stiff initially, which will change over time
How to Customize Cotton Twill Hats
Cotton twill can handle almost any decoration method well due to its tight weave structure. It’s exceptional for high-detail embroidery projects. Our customers have also had success screen printing on blank cotton twill caps and reported vibrant results. At CapBargain, we have also undertaken bulk customization projects on some of our bestselling cotton twill hats. The fabric's durability ensures decorations last longer without cracking or fading. Heat press applications work at standard temperatures.
What is Cotton Twill Used For?
The American headwear market offers a variety of caps made of cotton twill, with the most popular being cotton twill baseball caps. Cotton twill fabric is also used on caps with faded, washed-look styles. They can be used as work caps, uniform headwear, and in sports owing to the durability of the material. The fabric's strength makes it a great option for caps to be used outdoors daily.
TLDR: Difference Between Brushed Cotton and Cotton Twill
The core difference lies in construction and purpose. Brushed cotton prioritizes comfort and a premium feel through surface treatment. Cotton twill focuses on durability through specialized weaving. Brushed cotton feels softer but requires more care. Cotton twill offers superior longevity but may feel firmer initially.
What are the cap recommendations for Brushed Cotton?
What are the cap recommendations for Cotton Twill?
Conclusion: Choosing Between Brushed Cotton & Cotton Twill
Your choice should take the target market and the application into account. The softer, comfier brushed cotton caps showcase a premium aesthetic if your target audience is more into that. The cotton twill is more basic, tougher, and still softer than regular cotton. They both have their fair share of pros and cons.
At CapBargain, we stock both options to meet any requirement with wholesale hats—blank or customized. If you need tips on customizing hats for your team, you might be interested in reading this blog.
Hopefully, this blog made it easier for you to choose between the two fabric materials.
If choosing the right colors for your choice of hats is the challenge in front of you, check out our piece on how to choose the perfect hat colors.
Frequently Asked Questions
Which fabric shrinks more?
Brushed cotton typically shrinks more than cotton twill due to its looser fiber structure.
What's better for outdoor work caps?
Cotton twill wins for durability and stain resistance in demanding environments.
Is brushed cotton costlier than cotton twill?
Both command premium pricing, but brushed cotton often costs slightly more due to additional treatments on the fabric.
Do these fabrics fade differently?
Cotton twill holds color longer due to its tight weave structure.