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OTTO’s New T4 & T8 Fabrics vs. Cotton Twill: What You Should Know
There’s nothing quite like a good hat.
But you know what really makes a hat great?
The Fabric.
That’s because it’s literally the part that does all the heavy lifting. It keeps the shape and holds the design, and the best part? It will sit comfortably on your head from sunrise to sundown.
Now, most folks are familiar with cotton twill. It’s the classic choice. But lately, OTTO has been cooking up something new with its T4 and T8 polyester twill fabrics…and they’re turning heads for good reason.
Both are 100% polyester and both offer stretch, but each one brings its own flavor to the table.
So let’s get into it. What’s the real difference between these three fabrics? When should you go with tried-and-true cotton twill, and when is it time to reach for the stretchier (and shinier) stuff?
Here’s the lowdown.
Cotton Twill: The Familiar Favorite
Cotton twill is kind of like the flannel shirt of the fabric world. It’s dependable and it’s soft, and it’s been around the block more than a few times. Woven in that recognizable diagonal pattern, it’s breathable and holds shape well.
Let’s put it this way, it has a nice natural texture that most people just trust.
That said, cotton twill isn’t without its quirks. It tends to wrinkle and it doesn’t stretch, and over time, it might start to fade a bit (and especially after repeated washings or long days in the sun).
Still, it’s a solid pick for casual wear and everyday use.
Popular OTTO Styles in Cotton Twill
If the job calls for basic comfort and easy embroidery along with that traditional look, cotton twill still has plenty of gas in the tank.
T4 Polyester Twill: The Rugged Workhorse
Now here’s where things get interesting. T4 polyester twill takes the familiar feel of cotton and levels it up. It’s made from 100% polyester, but don’t expect that slick texture. That’s because T4 has a coarser and cotton-like surface with a matte finish. Still, it’s perfect for embroidery.
It’s heavier than most other poly twills, which means it holds up better under pressure. And it’s got some real bonus points: it’s dust resistant and anti-static and stretchable. So it not only looks good and lasts long, it also feels surprisingly comfortable when worn for hours.
- Heavyweight single-sided twill
- Durable with a cotton-style texture
- Matte finish for a clean, rugged look
- Dust and static resistant (no lint magnets here!)
- Built-in stretch for a better, more flexible fit
- Ideal for embroidery, heat transfer, and sublimation
Top OTTO Styles That Utilize T4:
- 9305-1: Structured mesh back trucker with street-smart style
- 1120-1: Seamless mesh back style that’s smooth up front and breezy in the back
- 930-1: Classic sporty style with a pro style profile
- 270-1: Seamless mid-profile baseball cap that plays well everywhere
- 19-4: "OTTO COMFY FIT" cap made for all-day wear
T4 is the kind of fabric that says, “Let’s get to work,” but it also does it without sacrificing comfort or good looks.
T8 Polyester Twill: The Stretchy Sophisticate
If T4 is the hardworking utility player, T8 is the smooth operator. It’s also made from 100% stretchable polyester, but it’s finer and softer, and it also feels more premium right out of the gate. It’s got twilled texture on both sides, which gives it a sleek finish inside and out (and that’s certainly a big step up in the comfort department!).
What really sets T8 apart, however, is the superior stretch. It bends and it flexes, and it fits like a dream. That alone makes it ideal for performance hats and flex fit styles.
And even though it’s lighter than T4, it still holds its shape beautifully. It's a more modern and fashion-forward fabric that wears well and looks even better.
- Double-sided twill for a smoother and high-end finish.
- Lighter and more stretchable than T4
- Perfect for flex fit caps and athletic looks
- Feels premium without being flashy
Top OTTO Styles That Utilize T8:
- 27-3: "OTTO COMFY FIT" cap with a perforated back
- 11-2: Sleek and stretchy, and with just the right amount of structure
T8 is the one you reach for when you want to elevate your cap game. It’s got that modern edge but it fits like it was custom-made.
So, Which One Should You Choose?
Well, that all depends on what you need your hat to do.
Cotton twill is still a winner for simple and classic looks. It’s breathable and reliable, and it gives off that vintage vibe people love. That’s why it’s great for low-impact wear and standard team gear, as well as for embroidery that doesn’t need a ton of stretch.
T4 is built for action. It’s ideal for hats that see heavy use. Think workwear, custom brand caps, or anything needing a little more durability and structure.
T8 is for comfort lovers and style-forward thinkers. If stretch and fit and a truly premium feel are at the top of your list, then this fabric’s the one for you.
When it comes down to it, there’s no one-size-fits-all answer…but there’s definitely the right fabric for the right job.
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