Buy a better gi
I find that some gi's will be like cradboard no matter what you do - especially the cheap ones. I kind of like it though, but I have switched to a lighter gi over the years .They tend to 'break' easier.
BTW: I NEVER use fabric softener of any kind. No need to put more chemicals in nature than there already is. I also try to avoid using the dryer. It's a waste of electricity and it shrinks the closes.
Finally lets be frank.. who really joined aikido to be comfortable?