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

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

When creating custom t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and print quality. Understanding the key differences between popular options—100% cotton, 50/50 blends, and tri-blends—helps you select the best material for your needs.

100% Cotton: Classic Softness and Breathability

100% cotton t-shirts are a timeless favorite for many, offering natural comfort and a soft feel that gets better with every wash.

Pros:
– Ultra-soft and breathable: Ideal for warm weather and sensitive skin.
– Excellent printability: Holds vibrant screen prints and DTG (direct-to-garment) inks well.
– Natural and biodegradable: Eco-friendly option for sustainability-focused brands.
– Comfortable drape: Feels familiar and classic on the body.

Cons:
– Prone to shrinking: Especially if not pre-shrunk; requires careful washing.
– Less durable over time: May wear out faster and develop pilling.
– Wrinkles easily: Requires ironing for a crisp look.
– Can stretch out: Especially with frequent wear and washing.

Best For: Everyday wear, promotional giveaways, retail apparel, and designs with bold, detailed prints.

50/50 Blend (50% Cotton / 50% Polyester): Balanced Performance

The 50/50 blend combines the best of both worlds—softness from cotton and durability from polyester—offering a practical, mid-range option.

Pros:
– Resists shrinking and wrinkling: More durable in the wash than 100% cotton.
– Affordable and long-lasting: Retains shape and color over time.
– Lightweight with slight stretch: Comfortable for active wear or layering.
– Good print surface: Works well with most printing methods.

Cons:
– Slightly less breathable: Polyester content can feel warmer than pure cotton.
– Can feel less soft initially: May not have the same “premium” hand-feel.
– Pilling potential: Especially with lower-quality blends or rough handling.

Best For: Active lifestyles, workwear, school events, and budget-friendly bulk orders where durability matters.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon): Premium Softness and Drape

Tri-blend fabrics offer a luxurious feel with a vintage-inspired look, combining softness, durability, and a unique aesthetic.

Pros:
– Incredibly soft and silky: Often described as “buttery” or “lived-in” from day one.
– Excellent drape: Flattering fit that moves with the body.
– Minimal shrinkage: Stable in the wash due to high polyester content.
– Vintage aesthetic: Slightly heathered look adds style and hides wear.

Cons:
– Higher price point: More expensive than cotton or 50/50 options.
– Less breathable than cotton: Rayon and polyester reduce airflow.
– Requires gentle care: Can be more delicate; avoid high heat to preserve softness.
– Limited color options: Often available in heathered or muted tones.

Best For: Fashion-forward apparel, boutique brands, gift items, and customers seeking a premium, soft hand-feel with a modern look.

Choosing the Right Fabric for Your Custom T-Shirt

Consider these factors when deciding:
– Intended Use: Everyday comfort (cotton), durability (50/50), or premium feel (tri-blend)?
– Climate: Hot and humid? Cotton breathes best. Need moisture-wicking? 50/50 or tri-blend may be better.
– Print Design: Detailed graphics and bright colors shine on cotton and tri-blends.
– Budget: Cotton and 50/50 are typically more budget-friendly than tri-blends.
– Audience Preferences: Focus on softness, sustainability, or performance?

By matching the fabric to your goals—whether it’s comfort, durability, style, or cost—you’ll create custom t-shirts that look great, wear well, and delight your customers.

How to Get the Best Price on High-Quality Custom T-Shirts (Bulk Discounts & Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, support a cause, or outfit a team—but only if you know how to balance quality and price. The key lies in understanding bulk pricing, selecting the right materials, and preparing your artwork properly. Here’s how to get the best value without sacrificing quality.

Understand Bulk Quantity Breaks to Maximize Savings

One of the most effective ways to reduce per-unit cost is by leveraging bulk quantity breaks. Most screen printers and custom apparel suppliers offer tiered pricing that drops significantly at certain volume thresholds.

• Know the Common Break Points: Typical quantity tiers are 25, 50, 75, 100, 250, and 500+. Prices often decrease sharply at 50 or 100 units, so ordering just above a tier can save you money per shirt.
• Order Strategically: If you need 45 shirts, consider ordering 50 to benefit from the lower rate. Factor in storage and future needs to justify slightly larger runs.
• Compare Quotes Across Suppliers: Request quotes from multiple providers at the same quantity to identify who offers the best value at each break point. Don’t assume the lowest base price equals the best deal—factor in shipping, setup fees, and quality.

Choose High-Quality Blank T-Shirts Wisely

The shirt itself is half the equation. A cheap blank can ruin even the best design. Prioritize durability, comfort, and longevity.

• Opt for Trusted Brands: Gildan, Bella+Canvas, Next Level, and Anvil are known for consistent quality. Premium options like Bella+Canvas 3001 offer a softer, more modern fit.
• Consider Fabric Composition: 100% cotton is classic but may shrink. A cotton-polyester blend (e.g., 50/50 or 60/40) resists shrinking, fades less, and feels softer—ideal for frequent wear.
• Check Weight (GSM): A midweight shirt (5.0–6.1 oz) offers the best balance of durability and comfort. Avoid sub-5 oz shirts for bulk orders—they often feel cheap.

Optimize Your Artwork for Lower Printing Costs

Artwork preparation directly affects printing efficiency and cost. Simple, well-prepared designs reduce setup time and ink usage.

• Simplify Your Design: Fewer colors = lower screen printing costs. Stick to 1–3 colors when possible. Each additional color increases setup and labor fees.
• Use Vector Files (AI, EPS, SVG): These scale infinitely without losing quality. If you only have a PNG or JPEG, ensure it’s at least 300 DPI and the exact print size.
• Outline Text and Convert to Paths: This prevents font issues when the printer opens your file. Always embed fonts or convert text to outlines.
• Specify Accurate Pantone (PMS) Colors: This ensures color consistency across large batches. Avoid complex gradients or photo-realistic prints unless using digital printing (which costs more at scale).

Select the Right Printing Method for Your Needs

The printing technique impacts both quality and price—especially in bulk.

• Screen Printing: Best for large, simple designs with few colors. Cost per unit drops dramatically in bulk. Ideal for 24+ shirts.
• Direct-to-Garment (DTG): Great for full-color or detailed artwork, but more expensive per unit and slower. Best for smaller runs or complex designs.
• DTF (Direct-to-Film) or Sublimation: Good for all-over prints or polyester blends, but higher setup costs. Evaluate based on design scope.

Request Samples Before Committing

Never order bulk without first seeing and feeling a sample. This confirms:

• Fabric quality and fit
• Print accuracy and durability
• Color matching to your brand

Many suppliers offer sample shirts at a low cost or even free for large orders.

Negotiate and Bundle Services

Especially for large orders, don’t hesitate to negotiate.

• Ask about waiving setup fees for repeat orders or large quantities.
• Bundle services like design help, packaging, or labeling to reduce per-unit handling costs.
• Inquire about discounts for paying upfront or referrals.

Final Tips for Best Value

• Plan Ahead: Rush orders often come with 25–50% surcharges. Allow 2–3 weeks for production.
• Check Return/Replacement Policies: Ensure the supplier covers misprints or defects—critical for bulk orders.
• Read Reviews: Look for feedback on quality consistency, customer service, and on-time delivery.

By combining smart bulk ordering, high-quality materials, and professional artwork, you can achieve premium custom t-shirts at a price that makes sense for your budget.