How to Choose Fabric for Custom Boardshorts
Published: 2026-01-08 · Last updated: 2026-10-06
Short answer: for bold printed boardshorts at good value, choose polyester-spandex; for a premium, abrasion-resistant surf short, choose nylon-spandex. Then add the finishes your market needs — quick-dry, chlorine resistance and UPF50+ — and confirm it all on a pre-production sample.
Fabric is the single biggest decision you make before production. It sets how your boardshorts feel, how they perform in and out of the water, how your print turns out and how long they last. This guide covers the fibres, weights and finishes that matter, and how to specify them for men's and boys' boardshorts.
Polyester vs Nylon vs Blends
| Fabric | Polyester — best value, quick-drying, ideal base for sublimation |
|---|---|
| Nylon | Softer, more abrasion-resistant, slightly more premium; common in high-end surf shorts |
| Spandex (elastane) | Added for 2-way or 4-way stretch so the shorts move and recover |
| Typical build | 88–90% polyester or nylon + 10–12% spandex |
| Weight | 100–160 gsm (light for warm markets, heavier for surf) |
| Certified options | GRS recycled polyester, OEKO-TEX certified fabrics |
The Two Base Fibers in Detail
- Polyester — quick-drying, durable and the best base for bold sublimation / all-over print boardshorts. The most cost-effective choice and the one most swim brands start with.
- Nylon — softer, more abrasion-resistant and slightly more premium; common in high-end surf boardshorts where a smoother hand and durability matter.
- Spandex (elastane) — added at around 10–12% for stretch so the shorts move and recover instead of bagging out.
Performance Features to Specify
- Quick-dry — essential for beach and pool use; the fabric should shed water and dry fast.
- Chlorine resistance — important for pool and training use, where ordinary fabrics fade quickly. See our chlorine-resistance guide.
- UPF50+ — sun protection, especially for kids' boardshorts and rash guards.
- Mesh liner or 2-in-1 short — support and comfort without separate underwear.
- Recycled (GRS) — a documented sustainability claim many European and US buyers now ask for.
Matching Print Method to Fabric
Sublimation / all-over print delivers the sharpest, most durable colour, but it needs a polyester base. Nylon takes solid dyeing and screen print well but not sublimation. Embroidery suits logos and small marks; screen print suits simple, bold graphics. In practice the fabric choice and the print method have to be decided together — see the printing guide for the full comparison.
How to Choose by Use Case
- Resort and casual swim: lighter polyester-spandex, 100–130 gsm, all-over or solid print.
- Surf and performance: nylon-spandex or heavier polyester, 4-way stretch, chlorine-resistant.
- Kids' boardshorts: soft polyester, UPF50+, OEKO-TEX certified, with a comfortable covered elastic waist.
- 2-in-1 and volley styles: 4-way stretch outer with a compression or mesh liner.
Bottom Line
For bold printed boardshorts and value pricing, choose polyester-spandex. For a premium, abrasion-resistant surf short, choose nylon-spandex. Whichever you pick, confirm stretch, colourfastness and print quality on a sample before you commit to bulk — it is far cheaper to fix a fabric on one sample than across a full order.
Frequently Asked Questions
Polyester is the best value and takes sublimation print brilliantly, so it suits bold all-over printed boardshorts. Nylon is softer and more abrasion-resistant, so it suits premium surf and performance shorts. Both work with spandex for stretch.
Most boardshorts sit between 100 and 160 gsm for a light, quick-dry feel. Lighter (around 100–120 gsm) suits warm climates and casual swim; heavier (140–160 gsm) gives a more substantial, durable hand for surf lines.
2-way stretch is enough for casual swim shorts; 4-way stretch is worth it for surf, training and 2-in-1 styles where the fabric needs to move in every direction.
Yes. We can supply GRS-certified recycled polyester and OEKO-TEX certified fabrics, with test reports available for your market.
Order a pre-production sample. It is the only reliable way to check stretch, colourfastness, print quality and how the fabric feels once sewn.
Not sure what fits your line? Contact WSD Beachwear and we will recommend the right fabric for your boardshorts.
Need Help Choosing Boardshorts Fabric?
We will recommend the ideal fabric, print and construction for your market.
Get a Free Quote