Comparison Table: Screen Printing, DTG, and Heat Transfer for Custom T-Shirts

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing the Best Fabric for Custom T-Shirts

Choosing the right fabric is crucial when designing custom t-shirts—it affects comfort, durability, print quality, and overall feel. The three most popular options are 100% cotton, 50/50 blends, and tri-blends. Here’s a detailed comparison to help you make the best choice for your needs.

100% Cotton

Pros:
– Soft and Breathable: Pure cotton is naturally soft and highly breathable, making it ideal for warm weather or active wear.
– Comfortable Feel: Offers a classic, familiar cotton texture that many people love.
– Excellent Printability: Holds ink well, especially for screen printing and direct-to-garment (DTG) printing, resulting in vibrant, detailed designs.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.

Cons:
– Prone to Shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable: More susceptible to wear, pilling, and thinning over time.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: While breathable, it retains sweat, which may feel damp during intense activity.

Best For: Everyday casual wear, promotional giveaways, eco-conscious brands, and designs with detailed or colorful prints.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Durability: Polyester adds strength, helping the shirt resist pilling and shrinkage.
– Less Shrinking: More stable in the wash compared to 100% cotton.
– Affordable: Often priced lower than premium cotton or tri-blends.
– Good Print Surface: Works well with screen printing and DTG, though colors may appear slightly less vibrant than on cotton.

Cons:
– Less Breathable: Polyester reduces breathability, which may make the shirt feel warmer.
– Slight Sheen: Can have a subtle synthetic look that some find less natural.
– Texture: May feel slightly rougher or less soft than 100% cotton or tri-blends.

Best For: Budget-conscious bulk orders, school or team apparel, workwear, and situations where durability and cost are top priorities.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Pros:
– Ultra-Soft Feel: Known for a luxuriously soft, lightweight, and slightly heathered texture—similar to a vintage tee.
– Excellent Drape: Flatters the body with a smooth, flowing fit.
– Reduced Shrinkage: More stable than 100% cotton thanks to synthetic fibers.
– Moisture-Wicking: Polyester helps pull moisture away from the skin.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends.
– Delicate Fabric: Can be less durable over time; may pill or snag more easily with heavy use.
– Printing Challenges: Requires careful settings for DTG printing due to rayon content; may not hold extremely fine details as well.

Best For: Premium gifts, boutique brands, fashion-forward designs, and customers seeking a soft, vintage-inspired look and feel.

Final Tips for Choosing

• Consider the Use: Is it for daily wear, sports, or a keepsake item?
• Think About Your Audience: Prioritize comfort, durability, or cost based on who will wear it.
• Match Fabric to Printing Method: DTG works best on cotton-rich fabrics; screen printing is more flexible across blends.
• Test First: Order samples to feel the fabric and test print quality before bulk production.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently select the ideal fabric to make your custom t-shirts stand out.

How to Get the Best Price for the Best Custom T-Shirts (Bulk Quantity Breaks, Artwork Tips)

Understand Bulk Quantity Breaks

One of the most effective ways to reduce the cost per unit when ordering custom t-shirts is by taking advantage of bulk quantity breaks. Most screen printing and direct-to-garment (DTG) companies offer tiered pricing—meaning the more shirts you order, the lower the price per shirt.

• Typical quantity tiers: 12, 24, 50, 100, 250, 500+
• Example: Ordering 100 shirts may cost $8 per shirt, while 250 could drop to $5.50 per shirt.
• Plan ahead: Even if you don’t need 250 shirts immediately, consider ordering in bulk to save and store extras for future use.

Pro tip: Some suppliers offer discounts for repeat orders—ask if they have loyalty programs or future order credits.

Choose the Right Printing Method

The printing technique significantly impacts both cost and quality.

• Screen Printing: Best for large quantities (50+ units) and simple designs with limited colors. Lower cost per unit in bulk and durable prints.
• Direct-to-Garment (DTG): Ideal for detailed, full-color designs and smaller runs. Higher per-unit cost but no setup fees.
• DTF (Direct-to-Film): Emerging option great for soft fabrics and vibrant colors, often more cost-effective than DTG for mid-sized orders.

Match the method to your design complexity and volume to save money without sacrificing quality.

Optimize Your Design for Cost Efficiency

Design choices directly affect production costs.

• Limit the number of colors: Screen printing charges per color. A 1- or 2-color design is significantly cheaper than a 5-color one.
• Simplify artwork: Avoid gradients and tiny details that require high-resolution printing or extra screens.
• Use vector files: Provide artwork in vector format (AI, EPS, or SVG) to avoid rework fees and ensure print clarity.

Prepare Print-Ready Artwork

A well-prepared design saves time and money.

• Resolution: For raster images (like PNG or JPG), use at least 300 DPI at actual print size.
• Bleed and safe zones: Keep critical text and graphics within the safe area (usually 0.5” from edges) to avoid trimming issues.
• File formats: Supply vector files when possible. If using raster, ensure high resolution and correct dimensions.

Many printers offer free artwork checks—take advantage to avoid costly errors.

Select the Right T-Shirt Style and Brand

Not all blanks are created equal—and price varies widely.

• Budget options: Gildan, Hanes, and Bella+Canvas 3001 offer quality at lower prices.
• Premium options: Brands like Bella+Canvas 3001 (slim fit), Independent Trading Co., or Next Level cost more but offer better fit and feel.
• Buy in bulk: Some suppliers offer discounts when purchasing blank shirts in large quantities.

Choose a shirt that fits your audience and budget—don’t overspend on premium tees unless necessary.

Get Multiple Quotes

Never settle for the first quote. Use online comparison tools or request quotes from at least 3–5 reputable suppliers.

• Compare: Price per shirt, setup fees, shipping, and turnaround time.
• Look for hidden fees: Some vendors charge for screens, color changes, or order changes.
• Ask about package deals: Some companies offer “design + printing + shirts” bundles at a discount.

Order Samples First

Before committing to a large run, order 1–2 sample shirts.

• Test print quality, color accuracy, and fabric feel.
• Confirm sizing and fit—this avoids costly reorders due to wrong sizes.

Many suppliers offer low-cost or free sample programs.

Time Your Order Strategically

Avoid peak seasons (e.g., back-to-school, holidays) when demand—and prices—rise.

• Off-season discounts: Some printers offer promotions in slower months (January–February, July–August).
• Early bird specials: Plan ahead and order early to lock in lower rates and avoid rush fees.

Final Tips for Best Value

• Consolidate orders: Combine multiple events or teams into one large order to maximize quantity breaks.
• Reuse screens: If you plan future reorders, ask if the printer can store screens for a fee—this cuts setup costs later.
• Negotiate: For very large orders (500+), don’t hesitate to negotiate pricing or request free extras like packaging or design help.

By leveraging bulk pricing, optimizing design, and choosing the right supplier, you’ll get high-quality custom t-shirts at the best possible price.