Who makes 100% cotton (not non-iron) Brooks Brothers quality button down shirts?

Twillory makes some nice shirts.

I have a few higher end dress shirts, of which I like the Thomas Pink ones the best.

Though I like lots of options, so buy two or three decent shirts at the same cost. I like Tommy Hilfiger trim fit for a go to and also, Izod makes damn good shirts for the $20.00 I spent on them and who cares if they don't last ten years, they were twenty bucks.

Page Two and no one's dropped a HK tailor yet?

Allow me: Jantzen Tailor Official Website

Send these guys your favorite shirt and they'll send back perfect replicas in whatever materials you specify.

Very reasonable prices.

I used them to reverse engineer a shirt from Louis Boston that I purchased at the old Filene's Basement. Subsequently optimized to my specs. What I got back lasted years of regular weekly use, and has since been cloned and continues to live on.

Bespoke version of a $250 shirt for < $100.

And their button quality - and selection - is uber.

Not to mention: 10 pages of pure cotton options: http://www.jantzentailor.com/purecotton.htm

Brooks just re-released the unfused OCBD again. Nothing in the collars or cuffs, but they are in the same price point as Mercer.
I visited all the HK tailors over the years. Can't recommend one over the next as most are using the mainland for the bread and butter portion of their business. And the HK bespoke is just as expensive as London, Italy or Japan. The aforementioned do much better softer tailoring and understand drape much better.

I took a chance and ordered (and received) my first four OCBD shirts from Kamakura and could not be more pleased.