Let's get straight to it — here's what actually matters on this one.

• Fit for your largest measurement (usually chest or waist) and have the rest tailored in — sizing down anywhere restricts movement and airflow.
• Look for reinforced stitching at stress points (underarms, inseam) — these are the first spots to fail, and failure there often means fabric rubbing raw against skin.
• Structured fabrics with a bit of stretch (cotton with 2-3% elastane) move better than 100% rigid cotton at larger sizes.
• Avoid fabric that's already tight from the store — you should be able to move your arms fully overhead without any pulling at the shoulder or side seam.

The fit-and-fabric-health takeaway: Tight-fitting fabric at larger sizes concentrates friction and traps more heat per square inch of skin — correct sizing is directly a comfort and skin-health decision here.

Next up: check out our guide on our sleeve length guide for men's shirts.