Home > Outdoor > Hiking

The Best Men’s Flannels of 2024

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.

Best Men's Flannels Hero(Photo/Erika Courtney)
Support us! GearJunkie may earn a small commission from affiliate links in this article. Learn More

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.

The Best Men’s Flannels of 2024


Best Overall Flannel

MuskOx Grand Flannel

Specs

  • Materials 100% BCI approved cotton
  • Fabric weight 300 g/m²
  • Garment weight 1 lb., 3.5 oz.
  • Fit Appropriately roomy
  • Best for 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.
Product Badge The Best Men’s Flannels of 2024

Pros

  • 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

Cons

  • Too much flannel for some
  • Cotton weft shows early pilling around the wrist
Best Budget Flannel

Jetty Arbor Flannel

Specs

  • Materials 100% cotton
  • Fabric weight 275 g/m²
  • Garment weight 1 lb., 2 oz.
  • Fit Appropriately roomy
  • Best for Replacing your sweatshirt
The Best Men’s Flannels of 2024

Pros

  • Comfortable cotton weave
  • Affordable price
  • Durable seams
  • Reasonable room under the cuffs

Cons

  • Not many — all design decisions were made to save money without sacrificing quality
Best Flannel Upgrade

Pladra Fireside

Specs

  • Materials 100% cotton
  • Fabric weight 330 g/m²
  • Garment weight 1 lb., 5 oz.
  • Fit Fitted, slender in the sleeves
  • Best for A better blanket shirt in just about every way
The Best Men’s Flannels of 2024

Pros

  • Luxuriously soft material
  • Heavy flannel remains pliable
  • Lifetime warranty

Cons

  • Wears too narrow in the sleeves to wear as an overshirt
Best Work-Ready Flannel

&SONS Yukon Field Flannel Shirt

Specs

  • Materials 100% BCI cotton
  • Fabric weight 290 g/m²
  • Garment weight 14.5 oz.
  • Fit Fits normal
  • Best for Tasks where functional and fashionable intersect
The Best Men’s Flannels of 2024

Pros

  • Impeccable craftsmanship
  • Burly BCI cotton fabric
  • Attention to detail is top shelf

Cons

  • Expensive (but you can get the shirt ½ off now)
  • Heavy buffalo plaid options aren't for everyone
Best Flannel Overshirt

Minus33 Sportsman Guide Shirt

Specs

  • Materials 80% wool and 20% recycled polyester
  • Fabric weight 385 g/m²
  • Garment weight 1 lb., 12 oz.
  • Fit Appropriately oversized
  • Best for Hardwearing tasks outside in mixed conditions
The Best Men’s Flannels of 2024

Pros

  • Comfortable against the skin
  • Impeccable craftsmanship
  • Good mobility

Cons

  • Expensive
  • Cuffs are snug when buttoned with the inside button
  • Runs a touch large. Buy down a size if you are in between sizes
Best of the Rest

ANIAN Berlino Flannel

Specs

  • Materials 80% recycled wool, 20% nylon
  • Fabric weight 500 g/m²
  • Garment weight 1 lb., 4 oz.
  • Fit Slim
  • Best for 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
The Best Men’s Flannels of 2024

Pros

  • Quality craftsmanship
  • Environment-friendly process
  • Well-priced for what you get
  • Weather resistant

Cons

  • Itchy
  • Chest pockets are small

Devium Boca Flannel Shirt

Specs

  • Materials 100% US cotton
  • Fabric weight 220 g/m²
  • Garment weight 14.5 oz.
  • Fit Fits normally
  • Best for The Boca is tough-wearing flannel that’s American enough to make a bald eagle shed a tear of Miller Lite
The Best Men’s Flannels of 2024

Pros

  • Entirely made in USA
  • Durable

Cons

  • Expensive, but the price reflects the backstory
  • A pencil slot would put the final nail in the shirt

Wellen Hazy Flannel

Specs

  • Materials 98% polyester, 2% Lycra
  • Fabric weight 254 g/m²
  • Garment weight 13 oz.
  • Fit Relaxed
  • Best for 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.
The Best Men’s Flannels of 2024

Pros

  • Well constructed
  • Fabric is soft and durable

Cons

  • Chest pocket is curved, not square, which makes it more decorative than functional
  • Expensive

Filson Alaskan Guide Shirt

Specs

  • Materials 100% cotton
  • Fabric weight 275 g/m²
  • Garment weight 1 lb., 4 oz.
  • Fit Fits normal if you size down
  • Best for The provenance of western American workwear, it is up for any task and wears casually around town
The Best Men’s Flannels of 2024

Pros

  • Durable cotton and construction
  • Classic styling
  • Pleated chest pockets
  • Several color options available

Cons

  • Expensive. There are better options in this price range
  • Would like to see the armholes flat-felled
  • Sizing is one size too big

Helly Hansen Classic Check Shirt

Specs

  • Materials 100% organic cotton
  • Fabric weight 370 g/m²
  • Garment weight 13.5 oz.
  • Fit Fits normal
  • Best for Durable enough for the shop with modern designs suitable for urban life
The Best Men’s Flannels of 2024

Pros

  • Durable
  • Modern styling
  • Organic cotton

Cons

  • Fabric weight is deceivingly light in the hand
  • Snug cuffs when buttoned

Proper Cloth Jackson Country Shirt

Specs

  • Materials 100% cotton
  • Fabric weight 210 g/m²
  • Garment weight 13.5 oz.
  • Fit Fits normal
  • Best for Casual dress day at the office and looking sharp on weekends
The Best Men’s Flannels of 2024

Pros

  • Beautiful cotton weave
  • Great color options
  • Customized fit
  • Attention to detail

Cons

  • On the expensive side
  • Not a heavyweight flannel for winter

Outerknown Cloud Weave Shirt

Specs

  • Materials 100% organic cotton
  • Fabric weight Unknown
  • Garment weight 1 lb., 7 oz.
  • Fit More tailored than the Blanket Shirt
  • Best for Casual wear and looking stylish
The Best Men’s Flannels of 2024

Pros

  • Soft and airy
  • Impeccable craftsmanship
  • Expensive
  • Not very durable
  • Limited patterns and colorways

Cons

  • A little slim in the arms
  • Airy weave may catch on sharp edges
  • Expensive

Roark Nordsman Long Sleeve Flannel

Specs

  • Materials 100% US cotton
  • Fabric weight Unknown
  • Garment weight 1 lb., 6 oz.
  • Fit Fits normal
  • Best for A well priced, warm flannel that's up for some hard work
The Best Men’s Flannels of 2024

Pros

  • Tailored shirt
  • Durable
  • Well priced
  • Snap closure

Cons

  • A little scratchy against the skin
  • Cuffs are snug around wrist

Mountain Hardwear Plusher

Specs

  • Materials 100% organic cotton
  • Fabric weight 300 g/m²
  • Garment weight 1 lb., 5 oz.
  • Fit True-to-size
  • Best for Cool weather overshirt
The Best Men’s Flannels of 2024

Pros

  • Great deal at $80
  • Soft and warm

Cons

  • 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

Smartwool Anchor Line Shirt Jacket

Specs

  • Materials 75% merino wool, 23% nylon, 2% other fibers
  • Fabric weight Unknown
  • Garment weight 1 lb., 5 oz.
  • Fit Appropriately oversized
  • Best for Wear it alone over a tee or layer it over a lightweight flannel
The Best Men’s Flannels of 2024

Pros

  • Comfortable against the skin
  • Good mobility
  • Snap closure

Cons

  • Expensive
  • We expected better finishings for a $200 overshirt
The author testing flannels at Oktoberfest in Munich; (photo/Steve Graepel)

Comparison Chart

FlannelPriceMaterialsFabric WeightGarment WeightFit
MuskOx Grand Flannel$134100% BCI approved cotton300 g/m²1 lb., 3.5 oz.Appropriately roomy
Jetty Arbor Flannel$80100% cotton275 g/m²1 lb., 2 oz.Appropriately roomy
Pladra Fireside
$155100% cotton330 g/m²1 lb., 5 oz.Fitted, slender in the sleeves
&SONS Yukon Field Flannel Shirt$190100% BCI cotton290 g/m²14.5 oz.Fits normal
Minus33 Sportsman Guide Shirt
$20080% wool and 20% recycled polyester385 g/m²1 lb., 12 oz.Appropriately oversized
ANIAN Berlino Flannel
$14880% recycled wool, 20% nylon500 g/m²1 lb., 4 oz.Slim
Devium Boca Flannel Shirt
$148100% US cotton220 g/m²14.5 oz.Fits normal
Wellen Hazy Flannel
$11898% polyester, 2% Lycra254 g/m²13 oz.Relaxed
Filson Alaskan Guide Shirt
$145100% cotton275 g/m²1 lb., 4 oz.Fits normal if you size down
Helly Hansen Classic Check
$100100% organic cotton370 g/m²13.5 oz.Fits normal
Proper Cloth Jackson Country Shirt
$130100% cotton210 g/m²13.5 oz.Fits normal
Outerknown Cloud Weave Shirt
$200100% organic cottonUnknown1 lb., 7 oz.More tailored than the Blanket Shirt
Roark Nordsman Long Sleeve Flannel
$100100% US cottonUnknown1 lb., 6 oz.Fits normal
Mountain Hardwear Plusher
$85100% organic cotton300 g/m²1 lb., 5 oz.True-to-size
Smartwool Anchor Line Shirt Jacket
$20075% merino wool, 23% nylon, 2% other fibersUnknown1 lb., 5 oz.Appropriately oversized
Best Men's Flannels — Pladra 1
This isn’t tank-top work — and we tested each flannel thoroughly to ensure that they had what it takes; (photo/Erika Courtney)

How We Tested Men’s Flannels

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?

Best Men's Flannels — Work
Material durability scores were weighted just as much as fit and mobility in our testing; (photo/Erika Courtney)

Testing History

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.

Buyer’s Guide: How to Choose a Flannel Shirt

There are plenty of flannels on the market, and we shouldered a number of them to find the best flannel of 2024; (photo/Steve Graepel)

Materials

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.

Best Men's Flannels — Outerknown Blanket Shirt
The Outerknown Blanket Shirt is made from 100% organic cotton, and is luxuriantly soft for it; (photo/Erika Courtney)

Fit

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)

Fabric Weights

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.

  • Lightweight flannels fall under 150-190 g/m²
  • Midweight flannels sit between 200-250 g/m²
  • Heavyweight flannels weigh over 250 g/m²

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)

Closure Style

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.

Price

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.

Jetty’s Arbor (left) uses exposed overstitched seams, while Proper Cloth’s Jackson (right) has fully flat-felled, double-stitched seams. Many flannels split the difference, like Filson’s Alaskan Guide, flat-felling the body, but flat-sewing the overstitched armholes; (photo/Steve Graepel)

Construction

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.

Best Men's Flannels — Sleeve Detail
(Photo/Erika Courtney)

FAQ

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.

Subscribe Now

Get adventure news and gear reviews in your inbox!

Join Our GearJunkie Newsletter

Get adventure news and gear reviews in your inbox!