Thicker than a button-down and thinner than a jacket, the best flannel shirts are extremely versatile: They’re a sweatshirt’s fuzzier cousin, but with a collar and buttons. After reviewing and sizing up the top-rated options, our best overall pick is Faherty Legend Sweater Shirt, which is extremely soft with a brushed texture. If you need warmth for chilly days, we recommend L.L.Bean’s Flannel-Lined Hurricane Shirt, a classic that’s built to last. From there, we drilled down to find winners for specific situations (such as a tailored flannel you can wear to work), body types (built-in stretch is key) and budgets (quality flannel for less than $90 does exist).
Contact us to discuss your requirements of custom flannel shirts. Our experienced sales team can help you identify the options that best suit your needs.
The best flannels combine comfort, warmth and style.
ILLUSTRATION: FORBES / PHOTO: RETAILERAt the end, you’ll find additional picks that didn’t make our initial cut but are still excellent and might be what you’re looking for. You’ll also get answers to readers’ commonly asked questions and styling tips at the bottom. Ahead, everything we highly recommend for the best flannel shirts.
MOST POPULAR
Faherty Brand
Sizes: XS to XXL | Materials: 65% recycled polyester, 30% viscose, 5% elastane | Colors: 23 total, including Solid Navy Twill and Bozeman Plaid | Pros: Mixes softness and stretch for all-day comfort | Cons: Fabric could pill
Built for colder months with a soft, sweater-like feel and relaxed fit, Faherty’s popular Legend shirt is heavyweight and has a bit of stretch, making it both comfortable and warmer than your typical flannel. While it commands a higher price tag, the quality stitching and attention to detail make this shirt a standout choice, and it comes in 23 patterns and colors.
What the reviews say: “This shirt is really like your favorite sweatshirt and favorite flannel rolled into one. Great choice for cooler weather. Can be worn with jeans or khakis. Can be worn by itself or over a base layer.” — Faherty
L.L. Bean
Sizes: S to XXXL | Material: 100% cotton | Colors: 4 total, including Blue and Coal | Pros: Pre-washed, stain-resistant, extra warm | Cons: Might be too warm for mild climates
For extra warmth and durability, L.L.Bean’s Hurricane shirt is lined with flannel inside and sturdy cotton on the outside that resists the elements (water, wind). It can double as a jacket, comes pre-washed for softness and gets better and better with every wear.
What the reviews say: “Great shirt. This is the second one. First one has more year's on than I can count with no rips, tears or holes. Just slightly faded from year's of wearing.” —L.L.Bean
Bonobos
Sizes: XS to XXL | Materials: 98% cotton, 2% elastane | Colors: 19 total, including Charcoal Houndstooth and Burgundy Sage Plaid | Pros: Slimmer fit and refined look | Cons: Lighter fabric misses a little warmth
When it comes to your office look, Bonobos’ top-rated shirt is smart option since it has a tailored fit and is cut from a lightweight flannel, so you can layer it under a coat or sweater. It’s made from mostly cotton for softness and the mix of subtle plaids and solid colors feels stylish and works well for corporate or formal settings.
What the reviews say: “One of my favorite shirts in my collection, have it in three different color ways. Soft, light, but structured nicely and fits to a T. Great shirt.” — Bonobos
Taylor Stitch
Sizes: XS to XXL | Materials: 100% organic cotton flannel chamois | Colors: 9 total, including Burnt Toffee Plaid and Birch Buffalo Check | Pros: Sturdy 7-ounce. cotton makes it extremely durable | Cons: Hemline is a little short for tall guys
Taylor Stitch is known for its commitment to classic design, quality and sustainability, with many garments produced in the U.S. with local manufacturing. Their top-rated Yosemite flannel is made from burly 7-ounce organic cotton, and has a modern warp and weft yarn structure to ensure it doesn’t fray or shrink in the wash.
What the reviews say: “This is a flannel above all other flannels. Warm but not too heavy. Soft and firm. I really love this shirt.” — Taylor Stitch
Todd Snyder
Sizes: XS to XXL | Materials: 52% cotton, 48% Tencel | Colors: 5 total, including Navy Twill and Olive | Pros: Cozy, smooth fabric| Pros: Not for extremely cold weather
Todd Snyder's button-down really stands out for its softness, which makes it easy for all-day wear. It’s made from an airy blend of cotton and Tencel, a synthetic fabric derived from plant cellulose with an extra-soft feel. This is a lighter weight flannel, so it’s not the warmest option but that might not be an issue on milder days, and you can layer a tee under this shirt.
What the reviews say: “Stylish and so comfortable and soft due to the brushed flannel, you will want to wear this more often than not. Fits true to size. Super soft, nice light oatmeal color. Extremely comfortable.” — Todd Snyder
Flint & Tinder
Sizes: S to XXL | Materials: 100% cotton loose-weave flannel | Colors: 7 total, including Harvest Plaid and Green Red Plaid | Pros: Durable, made to last | Cons: Sizing can be inconsistent
Flint And Tinder worked with a custom flannel mill to create this loose-weave twill flannel fabric. The shirt’s design takes its cue from classic work flannels, with a crossback construction that reinforces the yoke (i.e. the fabric that drapes over the shoulders). It’s a stylish, heavyweight flannel that’s built to withstand wear and tear, making this pick great for outdoor work, adventures or just relaxing.
What the reviews say: “This shirt is excellent, sturdy material. Fits great at its size and is great for cooler weather. Material is soft to the touch, feels like it will last a long time.” — Huckberry
Everlane
Sizes: XS to XXL | Materials: 100% cotton | Colors: 7 total, including Heather Navy and Heritage Charcoal | Pros: Slimmer fit and warm fabric | Cons: No added stretch
Everlane’s flannel is made from a midweight, 5.8-ounce cotton that’s brushed for softness and has a tailored fit. Classic details, like the button-closure front flap pockets add interest, and this pick comes in both solid and prints for a look you can dress up or down. The price is also affordable for such a well made shirt.
What the reviews say: “The shirt fits really well, the style is great, and the fabric is good for a warm layer. It's a classic piece with a casual look. It can be worn buttoned down. Love the fit.” — Everlane
Fair Harbor
Sizes: S to XXL | Materials: 63% recycled polyester, 36% rayon, 1% spandex | Colors: 12 total, including Cobalt Wine Plaid Dunewood Flannel and Wave Blue Plaid Dunewood Flannel | Pros: 4-way stretch offers plenty of give | Cons: No cotton in the fabric
For a laidback flannel you can live in during weekends, Fair Harbor’s has a relaxed fit and is cut from a sustainably made, performance fabric that offers 4-way stretch. It’s great for on-the-go days when you’re out and about and need a cozy shirt that’s breathable and comfortable.
What the reviews say: “Excellent fit and super comfortable. With flannel options everywhere this season it was nice to see such a pleasant color that is super soft and fits well. This flannel is the most comfortable garment I’ve ever worn.” — Fair Harbor
Lululemon
Sizes: XS to XXL | Materials: 62% recycled polyester, 33% Tencel lyocell, 5% elastane | Colors: 4 total, including Check Plaid Cassis Pomegranate and Heathered Smoked Spruce | Pros: Technical, moisture-wicking fabric | Cons: Might be too baggy for some
Lululemon’s foray into flannel is quite good: This just-released shirt offers “a technical take on a classic flannel,” as the brand puts it, with a stretchy, quick-drying fabric that drapes over your body rather than clinging to it. The oversized fit adds to the comfort factor, and this shirt can serve as your outer-layer on milder days.
What the reviews say: “Stays in shape after a couple washes. Love these. Purchased two last year and my husband wore them all the time. Really comfortable material and the perfect fit. This shirt is super high quality and slightly heavier than I thought it would be, which keeps me warm in the winter time.” — Lululemon
Abercrombie & Fitch
Sizes: XS to XXL | Materials: 100% cotton | Colors: 5 total, including Light Gray Plaid and Red Plaid | Pros: Heavyweight cotton provides extra warmth | Cons: Runs a little large
This flannel is made with extra heavy cotton to make sure the cold stays out—plus, a looser body allows for more layers underneath. If it’s cold enough for a sweater, but not quite cold enough for a winter jacket, this is an easy style as a grab-and-go option at an excellent price.
What the reviews say: “Classic plaid flannel with an updated style. A&F heavyweight flannel shirt jackets will last you a lifetime, getting better and softer with age and wear. The cut and fit are perfect, the colorways spot-on, and they're warm as heck, too.” — Abercrombie
Outerknown
Sizes: XS to XXXL | Materials: 100% organic cotton | Colors: 25 total, including Marine Fox Creek Plaid and Daylight Seaview Plaid | Pros: Organic cotton is sustainable and ultra-soft | Cons: Expensive
Founded by professional surfer Kelly Slater and designer John Moore, Outerknown emphasizes sustainability throughout their clothing. Their bestselling flannel shirt is cut from organic cotton twill, and finished with corozo buttons made from repurposed tagua palm nuts, as a natural alternative to plastic. It has a soft, blanket-like feel and comes in a stylish mix of colors and patterns. The fit is relaxed so you can layer it over a tee or henley during the cooler months.
What the reviews say: “Great shirt, comfortable, durable, looks great, fulfills every purpose. I ordered another the day after I received this one. I have to tell you, it is the most durable comfortable shirt I have ever put on my body.” — Outerknown
Outdoor Research
Sizes: S to XXL | Material: 100% polyester | Color: 6 total, icluding Tapenade and Pewter | Pros: Quick-drying, wrinkle-resistant | Cons: Runs small; consider sizing up
Outdoor Research’s flannel is woven from a sustainable fiber with built-in stretch that dries quickly and resists wrinkling and pilling, which makes it great for travel or those who don’t like to iron. This pick also comes in a wide range of colors and has a streamlined fit that works for most body types and activity levels.
Amazon
Sizes: S to 3XL | Material: 100% cotton | Color: 33 total, including Cedarwood Plaid and Mini Buffalo Plaid | Pros: High-quality stitching, soft feel | Cons: Runs large but shrinks after washing
A number-one bestseller on Amazon, this shirt is what one reviewer dubbed the “lord of the flannels.” The stitching is durable to ensure the shirt will hold up to wear and washing, the fabric is soft and this pick comes more than 30 colorways.
Allsaints
Sizes: XS to XXL | Material: 100% organic cotton | Color: Jet Black | Pros: Easily transitions from casual to formal outfits | Cons: Higher price point
Allsaints’s flannel has a corduroy-like texture and classic plaid style. It’s a modern button-down with a curved hem, the brand’s Ramskull embroidered on the chest and a relaxed fit. The vibe is refined-yet-laidback and the dark check looks great with jeans. At this price, though, it’s not a flannel to be chopping lumber in.
Madewell
Sizes: XS to XXL | Material: 100% cotton | Color: 4 total, including Old Spruce and Deep River | Pros: Soft against skin, has a lived-in feel | Cons: Slim fit may not appeal to all
Madewell’s bestselling flannel strikes the right balance between thickness and comfort, with a mid-weight weave that’s great when the temperatures fluctuate. You can wear this shirt under a jacket or over a t-shirt instead of a light sweater.
J. Crew
Sizes: XS to XXL | Material: 100% cotton | Color: 10 total, including Buffalo Check Grey Navy and Sunset | Pros: Comes in Classic, Slim, Tall fits | Cons: Some patterns might be too bold
Great for the office or work situations, J.Crew’s shirt comes in three different fits, including a slim option if you don’t want to be drowning in flannel. The fabric is soft for all-day wear and has a mid-weight that’s great for layering.
Dickies
Sizes: S to 4XL | Material: 100% cotton | Color: 7 total, including Black Ombre Plaid and Dark Olive| Pros: High quality cotton yarn-dyed flannel; affordable price | Cons: Too warm for transitional weather
Perhaps a flannel shirt just isn’t enough coverage for you. Dickies’s flannel jacket has a thicker, quilted construction and water repellent exterior to shield you from rain. Also nice: the fleece-lined hand warmer pockets.
REI
Sizes: XS to XXL | Material: 100% organic cotton | Color: 11 total, including Fields/Natural and Forge Grey | Pros: The flannel fabric holds up after multiple washes and doesn’t fade | Cons: Runs small
This bestselling shirt from Patagonia is made of a 6.5 oz. organic cotton flannel that’s more durable and substantial than other lighter weight versions. A straight hem allows for flexible styling—it could also be worn as a casual lightweight jacket—and the 2-button cuffs are adjustable so the sleeves stay put, no matter the activity.
Duluth Trading Co.
Sizes: S to 5XL | Material: 100% cotton | Color: 13 total, including Deep Sage Plaid and Gray Heather Multi Plaid | Pros: It’s available in tall sizes | Cons: Might shrink after drying
Duluth’s Free Swingin’ Flannel is designed with movement in mind: from swinging axes—like its name suggests—to hiking or working in the yard, the relaxed fit and deep shoulder pleats allow you to move without constriction. An inclusive size range fits many body types while design details like the hidden pencil pocket and a button-down collar help this pick stand out among other flannels.
Mack Weldon
Sizes: S to XXL | Material: 75% polyester, 21% Thermolite polyester, 4% merino wool | Color: Gulfstream Heather Fireside Plaid and Winestain Cabin Plaid | Pros: It doesn’t get too wrinkled after washing | Cons: It might fit tight in the chest and shoulders for larger sizes; consider sizing up
The Warmknit Flannel is made of a polyester-wool blend that’s engineered to simultaneously trap body heat and wick away moisture, so you’ll stay warm and not get too sweaty during wear. It’s also lightweight enough to be layered with other pieces and it can easily dress up, thanks to the slim fit.
Eddie Bauer
Sizes: S to 3XL (regular and tall sizes) | Material: 100% cotton | Color: 6 total, including Gray Smoke and Burgundy | Pros: The solid color options are great if you’re not a fan of plaid | Cons: It might need to be ironed after washing
With a soft-brushed, two-ply cotton flannel and a just-right fit that’s not too slim or boxy, Eddie’s Favorite Flannel is both comfortable and durable for all-day wear. The dual back pleats won’t restrict you, so feel free to move all you want. It also gives off an unexpected upscale look, thanks to the muted color palette and a button-down collar.
Banana Republic
Sizes: XS to XXL (regular and tall sizes) | Material: 100% cotton | Color: 7 total, including Light Blue and Navy Plaid | Pros: It’s roomy enough to layer with a thin sweater | Cons: There’s not a XS or S in tall
Perfect for both outdoor activities and casual outings, the Textured Flannel Shirt from Banana Republic has a slightly heavier weight that keeps you warm. Classic design details like two front flap pockets, a traditional point collar and a shirttail hem add to this shirt’s versatility; it looks stylish both on its own or worn open with a tee underneath.
Land's End
Sizes: S to XXL | Material: 100% cotton | Color: 13 total, including Red Buffalo Check and Alabaster Vintage Plaid | Pros: Cotton is brushed on both sides for ultimate softness | Cons: Returns aren’t free
Medium weight, warm enough, soft-brushed cotton...what more can you ask for in a flannel? This wardrobe staple from Land’s End offers plenty of coziness without the risk of overheating and the traditional fit and back pleat make it so comfortable, you won’t want to take it off.
Carhartt
Sizes: S to 4XL (regular and tall sizes) | Material: 100% cotton | Color: 7 total, including Asphalt and Basil | Pros: Triple-stitched seams add to its durability | Cons: It might be too boxy for slimmer builds
This heavyweight 8 oz. cotton flannel from Carhartt covers a lot: it’s warm without being too hot, it’s cozy soft but durable and there’s a slight natural stretch to it so you won’t feel constricted when reaching overhead. The spread collar gives it a modern, casual style while the garment washing process reduces shrinkage and further softens the brushed cotton.
When selecting flannel shirts for this list, we researched the market and fabric choices available, with an eye toward keeping the selection varied and emphasizing well-fitting, quality-made options for different fashion needs. We considered comfort level, price point, colors, sizes and fit options as well in our final recommendations.
Flannel is a soft woven fabric—usually cotton, but sometimes wool—that traces its routes from Wales as early as the 16th century. And since then, it’s been used in shirts. Flannel options are thicker than your typical all-cotton style, and often come in season-friendly prints and patterns. Here’s what else to keep in mind:
To prolong the life of your flannel shirt, it's always first recommended to follow care instructions on the garment's label. Typically, flannel shirts should be washed in cold water on a gentle cycle to prevent excessive wear. Avoid using harsh detergents or high-heat settings if you decide to put in the dryer. It’s not speedy, but air drying is usually the best way to maintain any shirt's softness and prevent shrinkage.
Brushed flannel is soft to the touch and has a cozy, textured feel, making it ideal for added warmth and comfort. Unbrushed flannel, on the other hand, has a smoother surface and may feel lighter. The choice between the two depends on your personal preferences for texture and warmth. Brushed flannel is typically best for colder weather while unbrushed flannel is better for layering and milder weather.
Flannel shirts are versatile and can be styled for many occasions. For a casual look, wear your flannel unbuttoned over a t-shirt or layer it under a denim jacket. In colder weather, flannel shirts can serve as mid-layers under a heavier coat or even as a jacket in and of itself. To dress things up a bit, pair your shirt with chinos or dress pants. Remember that this is fashion—there are no strict rules; experiment with different patterns and colors depending on the season and your personal look. At the end of the day, a flannel shirt is a style classic so it will serve you well in a number of different fashion situations.
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Flannel up this fall to hike, operate the tailgate grill, or tame the fall foliage. We've found the best classic wool, cotton, and technical flannel shirts for men.
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Ask the GearJunkie staff what their favorite season is, and it would undeniably be flannel season — doing fall chores, warming up by the fire, and simply working from home. As hot days give way to cool mornings, we’re all looking forward to flanneling up.
As low-pressure systems bring deep winter snow, we look forward to shouldering thick flannels that feel cozy at the cabin and capable outside. Our winter flannel buyers guide veers towards thicker, beefier shirts. All shirts this round are constructed from 200-plus grams per square meter (g/m²). These are the shirts we’ve been wearing après ski, closing out late fall chores, and layering up with to shovel the stoops.
To find the best flannels for 2024, we combed through stores, scoured the internet, and spoke with brands to find the best options available. To test the flannels, we wore them at work, hammered through weekend chores, brought them camping, and occasionally shouldered them as we tossed our legs over a bike.
What makes the perfect flannel? We looked at materials, cut, and construction, excusing color and patterns. Color schemes are more personal, and we’ll let you pick what looks best in your wardrobe.
To find the best flannels for men, scroll through to see all of our recommended buys or jump to the category you’re looking for. And once you’ve done that, check out our comprehensive buyer’s guide to unravel what makes a flannel a flannel, our chart to see how our choices stack up against one another, and our FAQ for any lingering questions. Grab your s’mores or pumpkin spice latte and get ready to arm yourself with what truly differentiates a quality flannel from the rest. The following flannels will last for seasons to come.
Editor’s Note: We updated our Men’s Flannels guide on February 28, 2024, to bulk up on the warmth factor and bring an entirely new line-up of thick flannels and shackets to get you through the cold of winter.
Best Overall Flannel
100% BCI approved cotton
300 g/m²
1 lb., 3.5 oz.
Appropriately roomy
Wear it for chores or to the bar. If you just want one flannel to punch up your wardrobe, the MuskOx Grand will land it with a TKO.
High-quality Egyptian and US sourced BCI cotton
Milled and sewn in Portugal
Built like a tank
Fat loop to hang the shirt in the nape of the neck
22 solid and plaid patterns to choose from
Too much flannel for some
Cotton weft shows early pilling around the wrist
Steve Graepel
Best Budget Flannel
100% cotton
275 g/m²
1 lb., 2 oz.
Appropriately roomy
Replacing your sweatshirt
Comfortable cotton weave
Affordable price
Durable seams
Reasonable room under the cuffs
Not many — all design decisions were made to save money without sacrificing quality
Steve Graepel
Best Flannel Upgrade
100% cotton
330 g/m²
1 lb., 5 oz.
Fitted, slender in the sleeves
A better blanket shirt in just about every way
Luxuriously soft material
Heavy flannel remains pliable
Lifetime warranty
Wears too narrow in the sleeves to wear as an overshirt
Steve Graepel
Best Work-Ready Flannel
100% BCI cotton
290 g/m²
14.5 oz.
Fits normal
Tasks where functional and fashionable intersect
Impeccable craftsmanship
Burly BCI cotton fabric
Attention to detail is top shelf
Expensive (but you can get the shirt ½ off now)
Heavy buffalo plaid options aren't for everyone
Steve Graepel
Best Flannel Overshirt
80% wool and 20% recycled polyester
385 g/m²
1 lb., 12 oz.
Appropriately oversized
Hardwearing tasks outside in mixed conditions
Comfortable against the skin
Impeccable craftsmanship
Good mobility
Expensive
Cuffs are snug when buttoned with the inside button
Runs a touch large. Buy down a size if you are in between sizes
Steve Graepel
Best of the Rest
80% recycled wool, 20% nylon
500 g/m²
1 lb., 4 oz.
Slim
This is a deconstructed work shirt that looks and wears great around town. While it's up for the task, we find it too refined for hard labor
Quality craftsmanship
Environment-friendly process
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Well-priced for what you get
Weather resistant
Itchy
Chest pockets are small
Steve Graepel
100% US cotton
220 g/m²
14.5 oz.
Fits normally
The Boca is tough-wearing flannel that’s American enough to make a bald eagle shed a tear of Miller Lite
Entirely made in USA
Durable
Expensive, but the price reflects the backstory
A pencil slot would put the final nail in the shirt
Steve Graepel
98% polyester, 2% Lycra
254 g/m²
13 oz.
Relaxed
A modern take on a vintage surf flannel. It’s an easy shirt to bring to the beach and is our go-to flannel for casual weekends.
Well constructed
Fabric is soft and durable
Chest pocket is curved, not square, which makes it more decorative than functional
Expensive
Steve Graepel
100% cotton
275 g/m²
1 lb., 4 oz.
Fits normal if you size down
The provenance of western American workwear, it is up for any task and wears casually around town
Durable cotton and construction
Classic styling
Pleated chest pockets
Several color options available
Expensive. There are better options in this price range
Would like to see the armholes flat-felled
Sizing is one size too big
Steve Graepel
100% organic cotton
370 g/m²
13.5 oz.
Fits normal
Durable enough for the shop with modern designs suitable for urban life
Durable
Modern styling
Organic cotton
Fabric weight is deceivingly light in the hand
Snug cuffs when buttoned
Steve Graepel
100% cotton
210 g/m²
13.5 oz.
Fits normal
Casual dress day at the office and looking sharp on weekends
Beautiful cotton weave
Great color options
Customized fit
Attention to detail
On the expensive side
Not a heavyweight flannel for winter
Steve Graepel
100% organic cotton
Unknown
1 lb., 7 oz.
More tailored than the Blanket Shirt
Casual wear and looking stylish
Soft and airy
Impeccable craftsmanship
Expensive
Not very durable
Limited patterns and colorways
A little slim in the arms
Airy weave may catch on sharp edges
Expensive
Steve Graepel
100% US cotton
Unknown
1 lb., 6 oz.
Fits normal
A well priced, warm flannel that's up for some hard work
Tailored shirt
Durable
Well priced
Snap closure
A little scratchy against the skin
Cuffs are snug around wrist
Steve Graepel
100% organic cotton
300 g/m²
1 lb., 5 oz.
True-to-size
Cool weather overshirt
Great deal at $80
Soft and warm
Locker loop is too small for the weight of the flannel. It will likely pull out
Chest pocket button backers leave the otherwise great flannel feeling unfinished
Steve Graepel
75% merino wool, 23% nylon, 2% other fibers
Unknown
1 lb., 5 oz.
Appropriately oversized
Wear it alone over a tee or layer it over a lightweight flannel
Comfortable against the skin
Good mobility
Snap closure
Expensive
We expected better finishings for a $200 overshirt
Steve Graepel
The author testing flannels at Oktoberfest in Munich; (photo/Steve Graepel)At GearJunkie, flannels are an extension of our everyday lifestyle. A shirt, a sweatshirt, a jacket — they are the most flexible garment we own. Unlike a tent, camp stove, or a pair of boots, we shoulder flannels daily, allowing us to put the brushed twill through the paces. We tested flannels at the office, and through the weekend, grinding through chores like cleaning the garage, raking leaves, or simply walking the dog on cool summer mornings.
Cozy in coach and a fashionable way to layer up, we always pack at least one flannel for travel. They’ve had our backs on 6-hour-long flights to Germany, Italy, France, and Slovenia, as well as transcontinental flights from Jacksonville to Boise. In warmer climates, we’ve flanneled up on cool nights on the Dariense Isabelia ridge in Nicaragua and high up on the Colombian Coffee Triangle.
To test flannels, we always start with how the material feels in the hand. We rate it for plushness, softness, and durability. We look at the fiber material, weave, and brushed finish. The material choice and finish are indicators of how the manufacturer envisions the flannel should be worn and used, and it points us in the direction of how we should test the shirt. We want to see if the two align and how they stack up to the marketing story told online.
During real-world consideration, we aim to wear flannels for what they were made to do. For example, hard work-oriented flannels are worn doing tasks that are hard on a shirt. Specifically, we want to know how it accommodates range of motion.
We want to know if we can swing a hammer or reach boards from the top shelf without exposing our torso or restricting motion in the arms. We also test it for snagging and durability. Does the flannel catch on wood, metal edges, or granite shards? Does it collect a lot of dust and grime?
Finally, we shoulder the flannels and evaluate them for fit. The best material and construction can’t fake a good fit. We test it for mobility and proper length. Does the shirt bind under the arms? Are the pleats and gussets appropriate? Does a straight-cut work without pleats? Are the arms or hem cut at a proper length or do they ride up when reaching? How does the shirt taper in the torso and arms?
Material durability scores were weighted just as much as fit and mobility in our testing; (photo/Erika Courtney)Steve Graepel has been leading the men’s flannel buyer guide since 2015. Over the span of 8 years, Graepel has seen over 200 flannel shirts, rigorously testing 94 flannels. Graepel has worked at GearJunkie as a contributing editor since 2009, testing everything from packrafts, to bike bags, sleeping bags, winter boots, and trail runners. His latest beat is travel pants and flannels. Before his time as a fashion blogger, he wrote for Travel Idaho, National Geographic Adventure, Patagonia’s Tin Shed, Trail Runner, and Gear Patrol.
Graepel has researched and tested flannels extensively — traveling, working, and camping in the high alpine desert of Idaho, Montana, and Utah, and traveling abroad in a variety of environments including Europe and South America. He continues to long-term test flannels year-round and searches for anyone who will listen to his yarns testing the brushed twill.
In 2020, we saw 47 flannels and listed 15 flannels on our men’s buyers guide. In 2021, we tested an additional 20 flannels, highlighting nine new flannels on our list. In 2022, we saw an additional 20 flannels, adding 12 new flannels. And this year we looked at 40 flannels, adding nine new heavyweight flannels to the buyer’s guide.
Each year introduces new styles and materials, and we try to reflect the best on the market of that year. Some stalwart flannels remain on the list, year after year. They are either so good, or so good of a deal, that they are tough to topple.
Flannels aren’t hard, but their simplicity makes it important to understand the details of a standout shirt. To keep a finger on the pulse, we read reviews from top sites and contact manufacturers directly. Steve Graepel has the owners of several companies on speed dial, and has had conversations with manufacturers and mills from around the world. It’s not uncommon for manufacturers to reach out to GearJunkie before they release a flannel to get a sense of the new lineup.
These relationships allow us to stay up to date on what makes flannels better every year, and keep an eye on sleeper flannels that just don’t have the marketing budget to get mass attention.
Wool used to own the flannel scene, and it has a lot of merits. It retains warmth when exposed to moisture, resists odors and UV light, and can block the wind. We love ANIAN’s heavyweight Berlino overshirt, which delivers all of these qualities with its wool construction.
While the Berlino weaves some nylon into the fabric, it still feels scratchy. For a more wearable wool, consider merino wool blended with synthetic. Both Smartwool and Minus33 weave some synthetic fibers with their merino and both feel very wearable against the skin. But there are other materials worth considering.
Cotton can be buttery soft and an obvious choice to wear next to skin. Pladra, MuskOx, and Mountain Hardwear all use high-end cotton. But not all cotton flannels are brushed to this extent. &SONS Yukon Field Flannel is lightly brushed and feels rougher. This makes it better for hardwearing activities in the yard or at the shop.
Some cottons are sourced from organic or Better Cotton Initiative (BCI) approved cotton fields. No synthetic pesticides or chemical fertilizers can be used in the cotton to achieve the rank of “organic cotton.” Pladra’s Fireside and Mountain Hardwear’s Plusher both use organic cotton.
BCI-approved cotton meets sustainable standards that minimize pesticides, boost water conservation, and support better working conditions for farmers. Our top choices are from MuskOx sources BCI cotton. Either way, meeting either of these standards costs more money to achieve and the cost is passed onto the buyer. Expect to pay a little more for shirts that list either of these certifications.
In addition to cotton, there are a growing number of synthetic and synthetic blends on the market. Some of our testers wear flannels while hitting the trails high in the Rockies.
If you break a sweat in flannel — say mountain biking, skiing, or running — we recommend considering a synthetic flannel. They are easy to care for and can be thrown in the washer and tumbled in the dryer. Roark’s Nordsaman uses a higher percentage of synthetic fibers which wicks moisture away from the body and has a DWR. Wellen’s Hazy will feel more plush and is our top pick for a synthetic flannel.
The Outerknown Blanket Shirt is made from 100% organic cotton, and is luxuriantly soft for it; (photo/Erika Courtney)Like any shirt, flannels are offered in a variety of fits, from athletic and tailored to grandpa-style. If you prefer a tidy look with a slimmer athletic fit, Proper Cloth’s Jackson will be a good choice. But it can be a tradeoff with mobility. Without Lycra woven into the fabric, gussets, or mechanical weave, a tight, form-fitting flannel can bind behind the shoulders. Shirts like Filson’s Alaskan Guide get around this by adding a pleat between the shoulders.
On the other end of the spectrum, MuskOx is oversized and has no pleating. The roomy cut still allows great mobility to reach and work without feeling too big.
When making a purchase, let your use case guide you to the right flannel fit. And if it’s a work shirt, consider sizing down for everyday wear. As an example, Filson work shirts are typically sized just short of Arnold Schwarzenegger. We always have to buy one size down when looking at Filson. &SONS Yukon Field flannel shares a lot of the same merits we like about Filson but the off-the-shelf fit is spot on.
Note that this review covers the best flannel shirts for men. Looking for a women’s flannel? We have another flannel buyer’s guide specifically for women.
Ranging from 150 to >300+ g/m², the fabric weight of flannel can vary widely, and the use profile varies with it; (photo/Steve Graepel)Short for grams per meter squared meter, g/m² is the weight of one square meter of fabric. Generally the heavier the weight, the thicker the material will be, the warmer that flannel will likely be. We generally follow the same ratings as we use in base layers.
As we stare down the dark days of winter, our flannel guide focuses on mid- and heavyweight flannels. At just over 200 g/m², Proper Cloth’s Jackson sits as our lightest-weight winter shirt. As you might guess, it is best for mild temperatures and casual wear. On the other end sits ANIAN’s Berlino, which uses a stout 500 g/m² wool blend and is supremely warm.
The numbers game isn’t hard and fast. Counter to the listed weights, Helly Hansen’s Classic Check uses a whopping 375 g/m² cotton material but weighs as much as Proper Cloth’s Jackson, a 200 g/m² cotton shirt. If you have doubts and can’t find evidence in the reviews, it is always best to try a shirt on and get a feel for the material.
A heavier fabric doesn’t imply the material will be softer — which the Berlino is not. That soft, velvety feeling comes from brushing the material, giving it that lofty plush nap. A fabric with more nap can also be warmer than a fabric without it. The raised fibers trap air warmed from your body and work best as an insulator when worn under a jacket that can keep that warm air from flushing away. One of our favorite flannels, Pladra’s Fireside, leaves the outside unbrushed (for durability) and brushes the inside (which traps heat better and feels incredibly soft).
Buttons never go out of style, but there’s a difference between a cheap plastic button and a brass button. Some flannels, like Smartwool’s Anchor Line (left), use snaps in place of buttons. &SONS Yukon (right) uses oversized bison horn buttons; (photo/Steve Graepel)Flannel closure is a contentious debate at GearJunkie, and many editors have a soft spot for snaps. Often seen on Western-style shirts, they hold well and are quick and easy to get in and out of. Granted, we are an active crew of reviewers who wear our flannels on runs and rides. Both Smartwool’s Anchor Line and Roark’s Nordsman flannels close with snaps.
While we love the usability of snaps, they can be problematic. Snaps disrupt the material by punching holes through the placket — that strip of material that runs dead center down the shirt. In rare cases, snaps can pull through, which we’ve experienced more than once on a snap-style shirt.
“If it ain’t broke, don’t fix it” — the button has been tried and true for some 5,000 years. Most buttons are constructed from hard plastics, though Devium and &SONS use horn. Jetty buttons their Arbor flannel up with metal buttons. Regardless of materials, we prefer big buttons for heavier materials, which is one more reason to consider Devium’s Boca. Their horn buttons are custom-made in Pennsylvania and are the size of a penny.
You can get into a flannel without having to spend a lot of cash. Better materials start to pry the wallet open. All flannels on this list are constructed from heavier-weight fabrics, and bargains get harder to find. We think that Jetty offers a solid deal at $75 and the Arbor is on sale now for $50.
The midprice of heavyweight flannels seems to fall in around $100, which creeps into a lot of money territory. And there can be a swell of uninspiring shirts in this range that lean on their brand recognition, bright patterns, and color schemes to open your wallet.
Here too, you get what you pay for, and it’s a good place to start to look at materials and construction to ensure you are indeed getting good value. Premium construction methods, like hand-sewn, double or triple stitching, and eco-conscious product development, start to tack onto the bottom line.
Unless there’s a backstory to support that extra cost, shirts priced over $150 leave you wondering if you are paying for someone’s mortgage. Topping out just below $200, we do feel that the attention to detail &SONS brings is of exceptionally high quality and warrants the expense.
While quality materials matter, the construction of the shirt is what often defines a quality shirt. The best will have flat-felled seams that roll the opposing material together and tack the seam down with a double stitch. The result hides all the cut edges, leaving a clean-looking, durable shirt inside and out. These shirts will often be double- or triple-stitched in high-stress zones, like the shoulders and sides.
While more durable, flat-felled seams can make a shirt bulkier, not every mill can pull off this level of construction. So flat-felled flannels tend to be more expensive.
Proper Cloth, &SONS and Helly Hansen use a flat-fell seam and vary the stitch count for extra durability where you need it most.
Many shirts use a more common overlock or surge stitch, where the two opposing panels are butted together and stitched down, leaving the seam’s edge raw on the inside. Using an overlock stitch is a much easier construction method, and since most sew houses can do it, the cost is (usually) reflected in the affordable price.
While flannel is often plaid, they are available in solids, too; (photo/Steve Graepel)The downside is some overlock stitches are left unfinished. Exposed, they can rub against the body, snag, and fray, which eventually will pull on the surrounding stitching. This gave us some pause when looking at the $200 Anchor Line from Smartwool. The shirt is fashionable and feels very good against the skin, so it still has its merits.
A good compromise is to flatlock the overstitching. It doesn’t hide the seams, but at least the overstitching is tacked down out of the way. This makes the seams less bulky than fully felled seams and costs less to sew. More importantly, it’s much more comfortable and practical when joining heavy-weight fabrics that creep over 300 g/m². Outerknown, Pladra, Anian, and MuskOx overstitched their flatlocked seams in the armpits.
When buying a shirt, look at the construction details. A well-constructed shirt will cost more in the short term but will last for years.
(Photo/Erika Courtney)What is flannel?
Traditionally a brushed twill made from wool, the original flannel was woven to keep Welsh sheep herders warm while tending the flock on temperamental winter days. Nowadays, the term flannel has expanded into cotton, synthetic, hemp, and blends with stretchy fibers. What unequivocally defines flannel is the brushed surface that lofts the yarns into a heat-trapping nap that gives it that super soft feel to the touch.
True flannels start from twill — a diagonal pattern like you find in jeans. Either the front or back can be brushed, giving it a soft insulating nap. To give a flannel that lofty fluffy feeling, a metal brush works the material’s surface, mechanically teasing the fibers until lofted into that fuzzy surface that traps air.
What flannels are most durable?
Flannel is achieved by brushing the fabric to tease fibers out, which act like an insulator. The rub is it can compromise durability. In short, the fibers are broken and become more prone to catching dust and grime, which can continue to break down the fibers. Contrastingly, lightly brushed flannels tend to be more durable. They don’t collect as much grime or catch as easily on wood splinters or metal edges.
Flannel comes in all forms these days. It’s unfair to box a shirt in or out of the flannel club. It might help to think of the base material sitting on a brush scale. At the far end is a smooth-faced, durable shirt. On the other is a soft and plush shirt.
Our top pick from MuskOX is a buttery soft flannel made from 300 g/m² organic cotton. The shirt is brushed on both sides and exudes flannel. The fabric is so thick that it will retain durability year after year. For mid-weight flannels, lightly brushed fabrics, like found in Devium’s Boca or &SONS Yukon will serve as better work shirts over, say Outerknown’s Cloud Weave which brushes loosely woven yarns.
What is the difference between flannel and plaid?
Flannel is a lofted fabric–regardless of the pattern. That fabric can come in a variety of solids and patterns, including the cross-hatched patterns, originally dating back to the Scottish culture to distinguish families and clans, we call plaid.
How do I choose a flannel?
Start with how and where you want to use it. If you intend to wear your flannel outside or as a jacket, consider a wool or insulated flannel. Minus33’s Sportsman Guide is great at blocking wind and light rain. We liked Devium’s front pockets and the low nap is very durable, but the cotton flannel is best worn on cool, dry days. Outerknown’s Cloud Weave is great for around town but lacks durability for hardwearing tasks.
We love Proper Cloth’s Jackson for its overall softness, quality, and general easy-wearing approachability. For more active pursuits, we liked how Wellen’s synthetic Hazy wicks moisture, without compromising that plush feeling we yearn for. But neither are as durable as Filson’s Alaskan Guide’s nearly bulletproof cotton flannel. The hard-tack surface is also the least plush shirt on our list.
Some work flannels, like those offered by Filson, can be oversized. We found the work-inspired Boca from Devium fit spot-on. In general, you will be happier if you try them on before you buy. If you can’t, it’s worth sizing down for a more tailored fit — especially when buying anything from Filson, which generally runs one size larger.
Like a tool in your toolbox, the best flannel will be the flannel that meets your needs. Take stock of how you want to use it, and then use our guide to find the best option for you.
What’s the warmest flannel?
The warmest shirt is the Pladra’s Fireside. The organic cotton fibers are fat and durable, with a low nap on the outside, its brushed in the inside to trap heat like down. Mountain Hardwear’s 300 g/m² Plusher is a good budget option for those who want a warm shirt that can also work as an overshirt.
Neither is as thick (or durable) as ANIAN’s Berlino wool, but the Fireside and Plusher wear more streamlined, whereas the Minus33 and Smartwool fit more like an overshirt. If you want to stay warm in wet weather, reach for wool or synthetic, and that’s where the Minus33 Sportsman Guide Shirt shines.
What’s the most comfortable flannel?
We loved Outerknown’s Cloud Weave for its über-soft feeling, both inside and out. It became the benchmark to test all other flannels for softness.
If you want a more heavyweight-hitting flannel, but don’t want to compromise softness, Pladra’s Fireside is a fantastic choice. While the outside isn’t brushed, the material is softer than a lot of other work-inspired shirts but still is inherently durable. For comfort against the skin, they brushed the inside to perfection.
How long do flannels last?
How long a shirt lasts is a combination of materials, construction, and use.
If taken care of, quality materials sewn together with flat seams will last for years. MuskOx, Devium, Roark, &SONS, and even the stylishly tailored Fireside from Pladra are all highly durable shirts. Any of these shirts are solidly constructed and will serve you well.
How often should I wash my flannel shirt?
How often you wash it depends on how you wear it. If you wear it daily as an overshirt, where you aren’t sweating directly against the fabric, you can get by with a few wears before you wash it. If you work out in it or are putting it to task with a shovel on a pile of dirt, you should wash your shirt.
Follow the instructions on the garment. While synthetics can be washed and dried on low, we recommend air-drying cotton shirts. They can shrink.
Wool shirts might need special care, like dry-cleaning. Never dry a wool shirt in the drier. The fibers can shrink significantly making it essentially unwearable.
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