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

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

When designing custom t-shirts, the fabric you choose dramatically impacts comfort, durability, appearance, and print quality. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends will help you pick the perfect material for your needs.

100% Cotton: Classic Comfort and Softness

Pros:
– Ultimate Softness: Feels cozy and natural against the skin, especially after a few washes.
– Breathable: Excellent airflow makes it ideal for warm weather or active wear.
– Eco-Friendly Option: Often preferred for organic or sustainable apparel lines.
– Great for Printing: Holds screen prints and direct-to-garment (DTG) designs well with vibrant results.

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk; always check garment specs.
– Less Durable: Can wear out faster with frequent washing and may pill over time.
– Wrinkles Easily: Requires ironing for a crisp look.
– Retains Moisture: Absorbs sweat but dries slowly.

Best For: Everyday wear, promotional giveaways, vintage-style tees, and eco-conscious brands.

50/50 Blend: The Balanced Performer

Pros:
– Durability: Polyester adds strength, reducing pilling and extending the shirt’s lifespan.
– Minimal Shrinkage: Resists shrinking better than 100% cotton.
– Affordable: Often priced between 100% cotton and tri-blends.
– Good Print Surface: Offers reliable results for most printing techniques.

Cons:
– Slight Sheen: Polyester content can give a subtle synthetic look.
– Less Breathable: Not as airy as cotton, which may be uncomfortable in heat.
– Can Feel Less Soft: May not feel as plush as cotton or tri-blends initially.

Best For: Uniforms, events, sports teams, and budget-friendly bulk orders where durability matters.

Tri-Blends: Premium Softness and Style

Pros:
– Buttery Soft Feel: Typically made from a mix of cotton, polyester, and rayon, creating an ultra-soft, lightweight fabric.
– Vintage Aesthetic: Slight drape and texture give a trendy, lived-in look.
– Excellent Drape: Flattering fit that moves with the body.
– Good Print Quality: Smooth surface ideal for detailed DTG prints.

Cons:
– Higher Price: More expensive than cotton or 50/50 options.
– Less Durable: Rayon can weaken when wet and may wear faster with heavy use.
– Special Care Required: Should be washed in cold water and air-dried to maintain quality.
– Limited Availability: Fewer style/color options compared to basic blends.

Best For: Fashion-forward apparel, boutique brands, gift items, and high-end custom designs.

How to Choose the Right Fabric

• Prioritize Comfort? → Go with 100% cotton or tri-blend.
• Need Durability on a Budget? → Choose a 50/50 blend.
• Want a Luxe, Fashion-Forward Look? → Tri-blend is your top pick.
• Printing Detailed Artwork? → All three work well, but tri-blends offer a smooth, premium canvas.
• Ordering in Bulk? → 50/50 blends often offer the best balance of cost and wearability.

Ultimately, the best fabric depends on your audience, use case, and brand image. Test samples when possible to feel the difference firsthand before placing a large custom order.

How to Get the Best Price for the Best Custom T-Shirt Site (Bulk Quantity Breaks & Artwork Tips)

When ordering custom t-shirts in bulk, getting the best price without sacrificing quality requires smart planning and insider knowledge. Whether you’re promoting a brand, organizing an event, or launching merchandise, these strategies will help you maximize savings through bulk quantity breaks and optimize your artwork for cost-effective production.

Leverage Bulk Quantity Breaks for Maximum Savings

Most custom t-shirt printing companies offer tiered pricing—known as “quantity breaks”—where the per-unit cost drops as your order size increases. To take full advantage:

• Order at Break Points: Aim to order at standard break points like 50, 100, 250, or 500 units. For example, the price per shirt might drop significantly at 100 pieces versus 90.
• Consolidate Orders: Combine orders with teammates, friends, or departments to reach higher tiers and reduce individual costs.
• Forecast Demand: Order slightly more than you need (within reason) to hit a lower price point. Extra shirts can be used as backups or future giveaways.
• Compare Vendors: Use quote tools from multiple top-rated sites (like Printful, Custom Ink, or RushOrderTees) to see who offers the steepest discounts at your desired volume.

Optimize Artwork to Reduce Printing Costs

Your design directly impacts printing costs. Follow these artwork tips to keep your project affordable:

• Limit Print Colors: Each additional color increases setup and printing costs (especially with screen printing). Stick to 1–3 colors whenever possible.
• Use Vector Files: Submit high-quality vector artwork (AI, EPS, or SVG) to avoid extra fees for file conversion or recreation.
• Simplify Design Elements: Avoid fine details, gradients, or tiny text that require advanced (and pricier) printing techniques.
• Choose One-Location Printing: Print on a single location (e.g., center chest) instead of multiple areas (front, back, sleeve) to reduce labor and setup charges.
• Standardize Sizes and Colors: Minimize variations in shirt color and design placement. More SKUs mean higher processing fees and longer production times.

Choose the Right Printing Method

Different printing techniques suit different budgets and designs:

• Screen Printing: Best for large, simple designs in bulk. Lower cost per unit with high volumes.
• DTG (Direct-to-Garment): Ideal for detailed, full-color designs on smaller runs. Higher per-unit cost but no setup fees.
• Heat Transfer or Sublimation: Great for all-over prints but usually more expensive. Best for performance wear or complex designs.

Match your method to your design and quantity to avoid overpaying.

Timing and Promotions Matter

• Order Off-Season: Prices may be lower during non-peak months (avoid holidays or back-to-school rushes).
• Look for Promo Codes: Subscribe to newsletters or follow vendors on social media for seasonal discounts and free shipping offers.
• Request Sample Quotes: Many sites offer free mockups and quotes—use them to compare options before committing.

By combining smart bulk ordering, efficient artwork, and strategic vendor selection, you can get high-quality custom t-shirts at the best possible price. Plan ahead, simplify where you can, and always compare options to ensure value without compromise.