Your ink is not getting cured. It absolutely has to reach 320 degrees to the bottom of your print, which means 330-340 at the surface. A hair dryer will not get it done. You can use a heat gun, but you have to gauge the temp as you do so with a thermo gun to ensure you are reaching temp. Any spot that didn't reach temp will crack and/or wash out. After curing do a stretch test.....the print should stretch with the material like rubber. If it cracks, it's not cured and will wash out.
Printing on polyester is another animal entirely....a little more goes into it. You can get away with printing regular plastisol on a 50/50 cotton/polyester blend but you have to watch out for dye sublimation when printing a light colored ink on a dark colored shirt. This is when the dye in the shirt mixes with the ink and your white print will be a shade of gray on a black shirt....or it will be pink on a red shirt, etc. You can overcome sublimation by doing a print/flash/print which means printing the first layer, half curing it (not to full temp.), then printing a second layer.
When printing on full or mostly polyester blends (like your 90/10), you need to use plastisol for polyester or add a polyester additive to your regular plastisol. Both of these lower the curing temp. to reduce or eliminate sublimation and melting the polyester.
You didn't experience any of these issues because you were not reaching curing temp. Same applies to water based inks for the most part.
Hope this helps,
Scott