Fabric Weights for Custom Rugby Shirts: Which One Should You Choose?
When designing a custom rugby shirt, one of the most important decisions is the fabric weight.
Fabric weight affects how the shirt feels, how durable it is, and when it’s most comfortable to wear. A lighter rugby fabric will feel more breathable and flexible, while a heavier fabric delivers the structure and durability associated with classic rugby shirts.
At CLIFTON, we offer four carefully selected fabric options for custom rugby shirts, each designed for different styles, climates, and uses.
Understanding the differences will help you choose the perfect option for your team, club, or event.
Medium-Weight Cotton Jersey (240gsm / 8oz)
Soft, durable everyday comfort
This is the most versatile fabric used in our rugby shirts.
The 240gsm cotton jersey offers a comfortable balance between durability and breathability, making it ideal for everyday wear.
It works particularly well for:
- Sports tours and club apparel
- Teams ordering shirts for regular use
- Warmer climates
- Groups who want a comfortable but structured rugby shirt
This fabric keeps the classic rugby look while remaining flexible and easy to wear.
For many teams, 240gsm is the perfect all-round choice.
Heavy-Weight Cotton Jersey (320gsm / 12oz)
Thicker hand feel with added structure
The 320gsm cotton jersey provides a heavier, more traditional rugby shirt feel.
This fabric has a noticeably thicker structure, creating a premium and durable garment that feels closer to historic rugby jerseys.
Benefits include:
- A strong, structured feel
- Increased durability
- A more premium appearance
- Better warmth in cooler climates
This option is popular with:
- University rugby clubs
- alumni teams
- heritage rugby designs
- premium club merchandise
If you want a rugby shirt with a classic heavyweight feel, this is the ideal choice.
Heavy-Weight Loopback Cotton (400gsm / 14oz)
Cozy loopback interior for warmth
The 400gsm loopback cotton is the warmest rugby shirt fabric we offer.
The interior features a soft loopback construction that adds insulation while maintaining the rugged appearance of a rugby shirt.
This fabric is perfect for:
- Cold-weather rugby shirts
- outdoor events and tours
- winter club apparel
- premium heavyweight garments
It combines the visual style of a rugby shirt with the comfort of a sweatshirt-like interior.
Polycotton Jersey (240gsm / 8oz)
Smooth surface ideal for vibrant all-over prints
This fabric is designed specifically for fully printed rugby shirts.
The polycotton jersey provides a smooth surface that allows colours and patterns to appear vibrant and consistent across the entire garment.
Advantages include:
- Ideal for all-over designs
- excellent colour reproduction
- durable and easy-care fabric
- lightweight everyday comfort
This option is often chosen for:
- touring rugby shirts
- bold custom designs
- club merchandise
- event apparel
How to Choose the Right Rugby Fabric
The best fabric depends on how the shirt will be worn.
Choose 240gsm cotton jersey if you want:
- an everyday rugby shirt
- comfortable medium-weight fabric
- a versatile option for most climates
Choose 320gsm cotton jersey if you want:
- a traditional heavyweight rugby shirt
- a structured, premium feel
- maximum durability
Choose 400gsm loopback cotton if you want:
- a warm winter rugby shirt
- extra insulation
- a cozy heavyweight garment
Choose 240gsm polycotton jersey if you want:
- vibrant all-over printed designs
- modern custom rugby shirts
- lightweight performance fabric
Why Fabric Weight Matters
Fabric weight influences three key factors:
Comfort
Lighter fabrics feel cooler and more flexible.
Durability
Heavier fabrics offer more structure and longevity.
Appearance
Different fabrics create different aesthetics, from lightweight sportswear to traditional heavyweight rugby.
Choosing the right fabric ensures your custom rugby shirt not only looks great but performs well in the conditions where it will be worn.
Final Thoughts
Fabric weight plays a major role in the feel and performance of a rugby shirt.
CLIFTON offers four premium options:
- 240gsm cotton jersey – versatile everyday rugby shirt
- 320gsm cotton jersey – classic heavyweight rugby
- 400gsm loopback cotton – warm winter rugby shirt
- 240gsm polycotton jersey – vibrant printed designs
Each fabric is carefully selected to deliver durability, comfort, and style.
Explore our full range of custom rugby shirts to start creating your design.
Originally published: 23 May 2023
Updated: 10 Mar 2026
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