Burnout T Shirts: What Decorators Should Know
What a burnout t shirt is, how the fabric is made, and how to print and press it without show through or dye migration.
Burnout tees for decorators: what the finish is, print and press notes, dye migration and show through checks.
A burnout t shirt is a poly cotton blend tee where a finishing process removes part of the cotton in a pattern, leaving sheer, see through areas made of the remaining polyester; because the fabric is light and partly polyester, decorate it with soft inks or transfers at the lowest workable heat and test every blank for show through and dye migration.
Key rule: treat a burnout blank as a lightweight polyester blend first and a cotton tee second. Its sheer zones change how ink lands, and its polyester share changes how heat behaves.
Part of the business and pricing guides in the DAX Learning Hub. Related: How to Buy Wholesale Blank T Shirts, What Is Jersey Fabric?, Tri Blend Shirts Printing and Polyester vs Cotton T Shirts.
Burnout vs Tri Blend vs Standard Jersey
| Blank type | Look and feel | Fiber picture | Print notes |
|---|---|---|---|
| Burnout jersey | Sheer, patterned see through zones; very light, airy hand | Poly cotton blend; cotton removed in the pattern areas, polyester left behind | Soft deposit; low heat; dye migration and show through tests; avoid placing art across the sheerest zones |
| Tri blend jersey | Soft, heathered, drapey | Polyester, cotton and rayon in one yarn mix | See the tri blend guide; heathered look and polyester share drive ink and heat choices |
| Standard cotton jersey | Opaque, even surface | Mostly or fully cotton | Widest ink and heat window; fewer migration concerns than poly blends |
| Cotton rich poly blend (no burnout) | Opaque, slightly smoother hand | Cotton with a polyester share | Polyester share still calls for migration checks at higher heat |
Read the table as a sorting tool, not a ranking. A burnout blank is chosen for its look. The trade off is a narrower decorating window than an opaque tee of similar weight.
How Burnout Fabric Is Made
Textile references describe burnout, also called devoré, as a process for blended fabrics. A treatment is applied in a pattern to a cotton and polyester blend, then heat activates it, and the cellulose fiber (the cotton) in those areas breaks down and washes away. The polyester stays, so the treated areas turn semi transparent while the untreated areas keep the full blend.
Because the effect depends on removing one fiber and keeping another, sources agree it does not work on 100 percent cotton. It needs a blend. Single jersey knits are commonly cited for t shirt burnout, and the share of cotton in the blend changes how sheer the finished zones look. A blank with more cotton tends to show a more open, sheer pattern; a blank with less cotton shows a subtler effect.
The process uses industrial chemistry. This page does not give recipes, chemical names or mixing steps. If your shop is considering doing burnout in house, rely on the chemical maker's technical data and safety data sheet (SDS), follow its handling, ventilation and protective equipment guidance, and follow local rules. Most decorators buy burnout blanks already finished by the mill.
Printing on Burnout Shirts
When you print onto a burnout blank that is already finished, you are printing on a lightweight fabric with two surfaces: the full blend areas and the sheer polyester areas. Ink lands differently on each. In the sheer zones there is less fabric to hold the deposit, so prints can look thinner or patchy there and heavy deposits can feel stiff on such a light garment.
Screen printing
Soft hand inks and light deposits suit the feel of the garment. Because burnout blanks carry a polyester share, choose inks the ink maker rates for polyester and poly blends, often a low cure or bleed resistant type. Follow the ink maker's technical data sheet for cure temperature and dwell, and check the cure with a wash or stretch test rather than by feel alone.
Heat applied transfers
Transfers can work, but they need a low temperature, polyester friendly setting from the transfer maker and a test press. A heavy transfer on a sheer, airy blank can change the drape. Keep designs moderate in size and weight unless the customer wants the contrast.
Placement
Look at where the sheer pattern falls before you set the print location. Art that crosses a very open area can read unevenly. Some shops place the print over a more solid zone or choose art with open shapes that work with the texture.
Heat, Dye Migration and Show Through
Dye migration happens when heat during curing or pressing lets dye from polyester fibers move into the ink or transfer, which can tint light colored prints. Ink makers and blank suppliers link the risk to polyester and poly cotton blends and to excess heat. A burnout blank is a poly blend, so the same general blend guidance applies; test each dyed color.
Common controls from ink and blank education:
- Use inks made for polyester or poly blends, such as low cure or bleed resistant types, per the ink maker.
- Cure at the lowest temperature the ink maker allows and avoid over curing or repeated heat passes.
- Ask about a blocker or base layer the ink maker recommends when printing light colors on dyed polyester blends.
- Let garments cool before stacking, and hold a test print for a day or more before running the full order, since migration can show up after printing.
- Test every new color and lot of blank; dye behavior can change between lots.
Show through is a separate issue. A light, sheer burnout fabric lets the garment color, and anything under it, show through ink and transfers more than a heavier opaque tee would. Light inks on dark burnout blanks may need an underbase, and the underbase adds weight and hand. Weigh that against the soft feel the customer chose the blank for.
When Burnout Blanks Fit an Order
Burnout blanks suit fashion, retail and event pieces where a light, vintage or textured look matters more than full color opacity. They are less suited to jobs that need fine detail, bright light colors on dark garments, heavy coverage or a uniform look across very large runs.
Before you quote, confirm fiber content and weight on the supplier spec sheet, ask about stock depth by color and size, and order samples to press or print. Check the wholesale blanks guide for the full blank checklist. If the customer wants softness without the sheer look, a tri blend or standard jersey may fit the job better.
Quote with a sample step built in. A short pre production test run on the actual blank and color is cheaper than reprinting a run that shows migration after a few days.
Frequently Asked Questions About Burnout T Shirts (FAQ)
What is a burnout t shirt?
A poly cotton blend tee where a finishing process removes cotton in a pattern, leaving sheer polyester areas next to areas that keep the full blend.
Can you screen print on burnout shirts?
Yes, with soft, light deposits and inks the ink maker rates for polyester blends. Test cure and check for dye migration on each color before production.
Can you heat press a burnout shirt?
Usually, at the low temperature setting the transfer maker gives for polyester blends, with a cover sheet and a test press first. Excess heat raises the risk of dye migration and scorch marks.
Do burnout shirts shrink?
Some shrink is possible, and it depends on the blend, knit and finishing. There is no single figure. Check the supplier spec sheet and care label, and wash test a sample if fit matters.
Why does my print show through a burnout tee?
The fabric is light and partly sheer, so garment color shows through thin ink. If light prints turn tinted after curing, that points to dye migration. Use polyester rated inks, lower heat and a blocker or underbase as the ink maker advises.
Supplier note: figures and settings here are hedged starting points that vary by blank, film, stone, leather, ink and certificate; confirm every claim against the supplier or manufacturer spec sheet, the garment care label and current certificates. No chemical names, recipes or eco or health claims are made on this page; for any burnout chemistry, follow the maker's technical data and SDS.
Browse more guides in the DAX Learning Hub, and check cities and dates on the DAX show schedule when you are ready to see blanks, inks and transfers in person.