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

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

When creating custom t-shirts on a budget, selecting the right fabric is crucial. It affects comfort, durability, appearance, print quality, and overall cost. Here’s a breakdown of the three most common fabric options—100% cotton, 50/50 blend, and tri-blends—to help you make the smartest choice.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warmer climates.
– Natural Fiber: Hypoallergenic and eco-friendly (if organic), appealing to eco-conscious buyers.
– Great Print Surface: Smooth surface ideal for vibrant screen printing and detailed designs.
– Widely Available: Easy to source at low prices from many suppliers.

Cons:
– Prone to Shrinkage: Can shrink up to 5–7% if not pre-shrunk; look for “pre-shrunk” labels.
– Less Durable: More susceptible to pilling and wear over time, especially with frequent washing.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: Holds sweat, which may feel damp during activity.

Best For: Casual wear, events, promotional giveaways where comfort and print clarity are top priorities. Ideal for screen printing logos or artwork.

50/50 Blend: Balanced Performance and Value

Pros:
– Affordable and Durable: Blends cotton with polyester (usually 50% each), offering better longevity and resistance to shrinking.
– Less Wrinkling: Holds its shape better than 100% cotton.
– Moisture-Wicking: Polyester helps draw moisture away, keeping wearers drier.
– Budget-Friendly: Often costs slightly more than basic cotton but provides improved performance.

Cons:
– Slightly Less Soft: Can feel coarser than 100% cotton, depending on fabric weight and finish.
– Less Breathable: Polyester content reduces breathability, which may be uncomfortable in hot weather.
– Pilling Risk: Lower-quality blends may pill after repeated washes.

Best For: Active environments, workplaces, or group shirts where durability and moderate comfort are needed. Good for both screen printing and direct-to-garment (DTG) printing.

Tri-blends: Premium Softness with a Higher Price

Pros:
– Exceptionally Soft: Typically a mix of cotton, polyester, and rayon (e.g., 50%/25%/25%), resulting in a buttery-soft, lightweight feel.
– Fashionable Drape: Provides a vintage, lived-in look that’s popular for trendy apparel.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic fibers.
– Breathable and Moisture-Managing: Combines benefits of all three fibers.

Cons:
– Higher Cost: Most expensive of the three options—may stretch your budget.
– Less Durable: Can be more delicate and prone to snagging or thinning over time.
– Special Care Required: Requires gentle washing to maintain softness and shape.
– Printing Challenges: The fabric’s texture and drape may affect print sharpness; DTG often works better than screen printing.

Best For: Fashion-forward brands, boutique merchandise, or premium giveaways where softness and aesthetics are worth the extra cost.

Final Tips for Choosing on a Budget

• Prioritize Use Case: Is the shirt for daily wear, an event, or active use? Match fabric to function.
• Check Weight (GSM): Heavier fabrics (e.g., 180–220 GSM) feel more substantial and last longer, even on a budget.
• Order Samples: Always test print and feel fabric swatches before bulk ordering.
• Consider Print Method: 100% cotton and 50/50 blends work best with screen printing; tri-blends suit DTG.
• Buy in Bulk: Larger quantities reduce per-unit cost across all fabric types.

Bottom Line: For tight budgets and classic appeal, 100% cotton delivers. For a balance of cost, durability, and comfort, choose a 50/50 blend. If softness and style are worth the investment, tri-blends elevate your custom tee—just plan for a higher price point.

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

Ordering custom t-shirts in bulk for events, teams, or promotions can be affordable—if you know the right strategies. By leveraging quantity discounts and smart artwork practices, you can significantly reduce your per-unit cost without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order size. The more shirts you order, the lower the cost per shirt.

• Know the Thresholds: Common quantity breaks are at 25, 50, 100, 250, and 500 units. For example, 24 shirts might cost $12 each, but 25 could drop to $8. Always ask for a price breakdown.
• Consolidate Orders: If possible, combine orders with friends, coworkers, or upcoming events to hit the next pricing tier.
• Mix Sizes and Colors (Wise): Many printers allow different sizes and colors within the same design at no extra charge—use this to meet minimums without overstocking one size.
• Avoid Going Just Over: Ordering 105 shirts when the break is at 100 might not save much. Stick close to the break points unless you truly need the extras.

Choose the Right Printing Method

The printing technique impacts both cost and quality.

• Screen Printing: Best for large, simple designs and orders of 24+ shirts. Setup costs are high, but per-unit cost drops sharply with volume. Ideal for solid colors and bold logos.
• Direct-to-Garment (DTG): Better for detailed or full-color designs and smaller runs. No setup fees, but higher per-shirt cost. Not cost-effective for large bulk orders.
• Heat Transfer or Vinyl: Suitable for very small batches or names/numbers, but less durable and not ideal for large bulk orders.

Optimize Your Artwork to Save Money

Design choices directly affect printing costs.

• Limit Print Colors: Each additional color in screen printing requires a separate screen and setup fee. Stick to 1–3 colors to keep costs low.
• Simplify the Design: Clean, bold graphics with minimal detail print faster and more accurately. Avoid gradients and tiny text.
• Use Vector Files: Provide artwork in vector format (AI, EPS, SVG) for crisp scaling. Raster images (JPG, PNG) may require redrawing, adding fees.
• Stick to One Print Location: Printing on the front only is cheaper than front and back. Each additional location increases labor and setup time.

Select Affordable, High-Quality Blank T-Shirts

The shirt itself makes up a big part of the cost.

• Choose Budget-Friendly Brands: Gildan, Hanes, and Bella+Canvas offer durable, soft options at lower price points.
• Standard Weights: 5.0–6.1 oz cotton shirts are typically cheaper than premium heavyweight or blended fabrics.
• Stick to One Style: Mixing shirt brands or styles can complicate printing and increase handling fees.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote.

• Compare 3–5 Printers: Use online quoting tools or request custom quotes from local and online vendors.
• Ask About Hidden Fees: Confirm if setup, screens, or art correction are included. Some companies waive fees for bulk orders.
• Negotiate for Loyalty or Referrals: Mention future orders or offer to refer others—many printers will discount to secure repeat business.

Final Tips for Maximum Savings

• Order Off-Season: Some printers offer discounts during slower months (e.g., late winter).
• Avoid Rush Fees: Plan ahead—standard turnaround is cheaper than rush service.
• Proof Everything: Approve a digital or physical proof to avoid costly reprints.

By combining bulk quantity breaks, simple artwork, and smart vendor choices, you can get high-quality custom t-shirts at the lowest possible price. Plan early, design smart, and always compare options.