Where light wins
Hot and humid markets, summer campaigns, giveaways and promotional runs where the shirt is a carrier for a logo rather than a garment. A 160–180gsm tee at volume is the cheapest credible option.
It also ships better: lighter fabric means lower freight per piece, which matters more than the unit price on large runs.
Where light loses
White. Under 160gsm, white jersey is visibly sheer under studio light, and twice as sheer in daylight. If the shirt is white and light, buyers will notice before they notice the design.
Heavy ink. A thick plastisol deposit on a light jersey causes the fabric to corrugate around the print after a few washes. Light shirts want thin ink or DTG.
- Avoid white below 160gsm for retail.
- Avoid thick plastisol on light jerseys — the fabric puckers around the print.
- Light fabric hides a bad collar less: the neckline is the first thing to distort.
The 180–200gsm middle
180–200gsm is the practical compromise: light enough to be cheap and cool, heavy enough not to be sheer and to hold a screen print. Most promotional tees live here.
This is also where tubular construction shows up, because a tubular body has no side seams — cheaper to make, and it removes two seams that could pucker.
What we hold
We hold 6 styles at 200gsm or below, from $3.00 — including an 180gsm tubular crew that goes to 6XL, and polyester activewear at 160–170gsm.