The Custom Heavyweight T-Shirt Trend Brands Can’t Ignore

If you follow t-shirt trends, you’ve probably noticed a new heavyweight champ has been crowned. Weighing in at around 6.5 ounces per square yard, these extra-hearty customizable tees pack upwards of double the fabric density of traditional custom t-shirts, giving a robust, quality feel that can truly pack a punch.

Whether you’re looking to make a statement with a promotional product or beef up your bespoke apparel offerings for resale, giveaways, or an event, it’s worth considering the key characteristics of a custom heavyweight t-shirt so you can be sure it’s the right style for your style and budget.

What Are Heavyweight T-Shirts?

Heavyweight t-shirts, as their name suggests, have thicker, more substantial construction than average tees. Typically, these shirts register around 1.5X to even 2X the weight of standard tees at roughly 6-10 ounces per square yard. (Though some super-heavyweight tees can get into the teens.)

These shirts feature visibly fuller composition with a structured drape. They may or may not be bigger than any other t-shirt from a surface area perspective — while some may be oversized, the “heavyweight” moniker is less about surface dimension than it is density. It’s also not necessarily a matter of quality, as heavyweight tees — like any other apparel option — can vary in quality by brand and by individual lines within a brand (though the quality bar is generally higher).

Even thickness may not be the start and end of the description here. While physical thickness is definitely the most recognizable quality of a heavyweight t-shirt, the other part of the equation is weight, which factors in fabric type and density. Some of these shirts can feel as thick as a sweater, or even as durable as denim.

While these shirts were once associated more with workwear brands — like the classic Carhartt Workwear Pocket Short Sleeve T-Shirt — they’ve become increasingly common in athletic and casual brands, like the Hanes Unisex Retro Beefy T-Shirt.

Lightweight vs. Heavyweight T-Shirts: Key Differences

In a word: the key difference between light and heavy t-shirts really is weight. If you’re wondering why extra material on a shirt might (or in some cases, might not) be a good thing, heavyweight tees aren’t universally better or worse than standard tees — whether they’re right for you is a matter of what you’re looking for.

Here’s a breakdown of some of the key differences between the two styles.

Why Custom Heavyweight Shirts Are Trending

One reason heavyweight shirts are trending is because t-shirts are always trending, and heavyweight options represent a rare innovation on a timeless staple. Another reason could be that celebrities are wearing them (for roles and on the street), talking about them, and even designing their own apparel lines with them.

But why are some of the biggest names in movies, TV, and music swearing by heavyweight tees? It could have something to do with the fact that these shirts:

• Are consistently more durable than standard-weight shirts
• Boast a premium feel
• Harken back to a bygone era of apparel with a vintage-inspired look
• Promote a roomier fit that aligns with trends in oversized garments
• Are better able to maintain their size and shape with proper care
• Can be easily customized with long-lasting t-shirt printing and embroidery applications

How Brands and Creators Are Using Custom Heavyweight Tees

Since heavyweight tees have a premium feel and ultra-durable construction, they’re the ideal canvas for brands and creators who want their company logo shirts and branded apparel to reflect quality, style, and exclusivity.

Here are just a few of the ways you can follow the heavyweight trend:

• Retail: If you’re looking to sell your custom heavyweight t-shirts, you can charge more for these than standard-weight tees while raising the quality bar for your brand.
• Promotional Giveaways: As a tradeshow or conference giveaway, these shirts’ quality reflects your brand’s quality and helps create a lasting impression.
• Fan Merch: Content creators, influencers, and artists can use custom heavyweight tees to offer their fans a more tangible way to support their work.
• Employee Apparel: You can get an employee morale boost when you use these upgraded tees as corporate gifts.

The key to getting the most out of heavyweight shirts is to keep in mind that they can be used in all the same ways standard shirts can, but their unique properties offer enhanced longevity, presentation, and utility — which come with premium per-unit costs.

Top Customization Methods for Heavyweight Shirts

Since heavyweight t-shirts can be made of virtually all the same materials and produced in essentially the same way as lightweight t-shirts, they can be customized similarly, too. If you’re looking to create a unique garment — whether it’s a promotional product, branded apparel, an event piece, or something else entirely — you’ve got a handful of printing options to choose from.

Screen Printing

Screen printing is the most common customization option for t-shirts across the board — heavyweights included. This process involves creating a stencil (AKA, screen) for each color included in the design and pressing ink through it onto the garment.

Best for: Bold, vibrant designs, especially for large-quantity orders

Embroidery

Embroidery is another popular printing option for heavyweight t-shirts. As you might already be imagining, it uses thread to stitch designs directly onto the fabric, giving garments a textured, bespoke, tactile feel.

Best for: Logos, small graphics with minimal detail, and designs that require a more distinctly custom look

Direct-to-Garment

Direct-to-garment, or DTG, printing uses a specialized printer to apply ink directly to the fabric. Think of it like using an office printer, but instead of paper, it’s heavyweight t-shirts. This high-tech modern printing method enables printers like ours to print high-quality designs en masse.

Best for: Complex designs, photographs, and designs with many colors

Direct-to-Film

Direct-to-film (DTF) transfers involve digitally printing a design onto a special film (as the name suggests) and using heat to transfer the design onto a shirt. The result is a durable, vibrant, detailed print that can be applied to virtually any material.

Best for: Both large and small orders, detailed designs, dynamic colors, virtually all fabric types

Care Tips for Long-Lasting Wear

First and foremost (stop me if you’ve heard this one before): Check the care instructions on the label. If you want to make printed t-shirts last as long as possible, that’s always step one.

The truth is, just like the t-shirts themselves, there is no one-size-fits-all approach to caring for these garments since fabric and manufacturing methods can vary widely. But if you want some general tips for making these already long-lasting t-shirts last as long as possible, here are some rules of thumb:

• Turin It Inside-Out: If you’ve got a custom design on the outside, this helps protect it from physical abrasions.
• Keep It Cold: Don’t just trust the standard presets of your washing machine — the hotter the water, the greater the risk for shrinkage, even for shirts with greater structural integrity like these.
• Keep It Gentle: As with any precious garment, keeping wash and dry cycles as gentle as possible helps promote longevity.
• Mind the Colors: More fabric also means more dye, so it’s helpful to keep these tees with similar colors in the wash to prevent bleeding — both to the garment and from it.
• Tone Down the Detergent: Look for detergents with limited chemical additives and gentle ingredients — harsher cleaning products can deteriorate the color faster.
• Lower the Drying Heat: If possible, always opt for air-drying your heavyweight t-shirts to ensure the lowest possible impact on their shape. These tees may be less prone to shrinkage, but they aren’t 100% immune.

How to Choose the Best Heavyweight T-Shirt

While the weight and thickness of standard t-shirts aren’t usually particularly noticeable from product to product, those of heavyweight tees can be. At the end of the day, the best litmus test is feeling them yourself if possible, and keeping in mind that more weight generally means more fabric, which typically translates to:

• Greater durability
• Increased heat retention
• Higher per-unit costs
• More structured drape

But if you can’t feel the shirts firsthand (i.e., you’re ordering online), keep in mind that typical t-shirts’ weight clocks in at around 4-5 ounces per square yard, and that heavyweight t-shirts come in at generally 6-9 ounces. For reference, jeans are around 12-13 ounces per square yard, so you can expect something closer to a light sweater or flannel, but with the softness and flow of a t-shirt.

Since there’s a wider range of feel and structure for heavyweight shirts, think about your unique needs first. If you’re looking for a lighter, more fluid structure, try to find a shirt that’s closer to the 6 ounce range (like the 6.1 oz Comfort Colors Heavyweight T-Shirt); if you want to maximize thickness, heat retention, and durability, look for something around 7.5 or above (like the Shaka Wear Max Heavyweight T-Shirt).

And whatever your custom apparel needs, RushOrderTees is here to help with a live design studio and a range of shipping options to meet your budget and deadline.

Related Reading:

• A Guide To T-Shirt Styles For Any Occasion
• Avoid These 7 Promotional Product Design Mistakes
• 79 Company Swag Ideas That’ll Impress
• How to Choose Apparel Colors that Match Your Brand Identity