Comparison Table: Screen Printing vs. DTG vs. Heat Transfer for Bulk Custom T-Shirts (Cheap)

Guide to Choosing Fabrics for Bulk Custom T-Shirts Cheap: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

When ordering bulk custom t-shirts at a low cost, fabric choice plays a crucial role in comfort, durability, print quality, and overall value. The three most common fabric options—100% cotton, 50/50 blend, and tri-blends—each come with unique pros and cons. Here’s a breakdown to help you choose the best option for your budget and needs.

1. 100% Cotton

Best for: Classic feel, breathability, and softness.

• Pros:
  • Soft, natural feel against the skin.
  • Highly breathable—ideal for warm weather and active wear.
  • Excellent for screen printing; ink adheres well.
  • Biodegradable and eco-friendly.
• Cons:
  • Prone to shrinking (especially if not pre-shrunk).
  • Less durable over time; may wear or pill with frequent washing.
  • Can wrinkle easily and lacks stretch.

Budget Tip: Look for 5.3 oz to 6.1 oz “value-weight” 100% cotton shirts—they offer a good balance of quality and low cost for bulk orders.

2. 50/50 Cotton-Polyester Blend

Best for: Durability, affordability, and low maintenance.

• Pros:
  • More durable and resistant to shrinking and fading.
  • Lightweight and slightly more wrinkle-resistant.
  • Often cheaper than 100% cotton due to lower material cost.
  • Good for both screen printing and DTG (direct-to-garment) printing.
• Cons:
  • Less breathable than 100% cotton.
  • Can feel slightly synthetic or less soft to some wearers.
  • May retain odors more than cotton.

Budget Tip: 50/50 blends are often the most cost-effective for large orders—great for promotional events, staff uniforms, or giveaways.

3. Tri-Blends (Usually Cotton/Polyester/Rayon)

Best for: Softness, drape, and a premium look on a moderate budget.

• Pros:
  • Exceptionally soft with a silky, vintage feel.
  • Great drape—ideal for fitted or fashion-forward styles.
  • Resistant to shrinking and fading (better than 100% cotton).
  • Great for DTG printing with vibrant color results.
• Cons:
  • More expensive than 100% cotton or 50/50 blends.
  • Less breathable due to higher synthetic content.
  • May wear faster with heavy use or frequent washing.

Budget Tip: While pricier per unit, tri-blends can still be affordable in bulk—consider them for premium giveaways or customer appreciation gifts.

Final Recommendation for Cheap Bulk Orders

For the best balance of cost, comfort, and printability in bulk custom t-shirts:

• Choose 50/50 blends if budget is your top priority and durability matters.
• Choose 100% cotton if you want a classic, breathable feel and plan to print simple designs.
• Choose tri-blends if you’re aiming for a softer, more stylish shirt and can stretch your budget slightly.

Always request fabric samples before placing large orders to ensure quality and comfort match your expectations.

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

Ordering bulk custom t-shirts can be a cost-effective way to promote your brand, event, or team. To get the cheapest rate without sacrificing quality, follow these proven strategies focused on quantity breaks and artwork optimization.

Leverage Quantity Breaks for Lower Per-Unit Costs

Most screen printing and promotional apparel suppliers offer quantity breaks, meaning the price per shirt drops significantly as your order size increases. Here’s how to maximize savings:

• Order at or just above break points: Common break points are 50, 100, 250, and 500 units. For example, ordering 100 shirts might cost $10 each, but 250 could drop to $6 each — a 40% savings. Even if you don’t need 250 shirts immediately, consider ordering extra for future use.

• Split sizes and colors within the same design: Many suppliers allow size and color variations without increasing setup costs, as long as the design remains unchanged. This lets you meet quantity breaks without limiting your order’s usefulness.

• Consolidate orders across teams or events: If you’re part of an organization, combine orders from different departments or upcoming events to reach higher tiers and reduce overall cost.

Optimize Your Artwork to Reduce Printing Costs

Artwork complexity directly impacts printing prices. Simplify your design to save money:

• Limit the number of print colors: Most screen printers charge per color per location. A 1-color logo is far cheaper than a 4-color design. Convert your artwork to a single PMS (Pantone) color if possible.

• Use vector artwork (AI, EPS, or PDF): High-quality vector files reduce setup time and prevent rework fees. Avoid low-res JPEGs or PNGs that need redrawing.

• Minimize print locations: Printing on just the front is cheaper than front + back or sleeves. Stick to one location unless absolutely necessary.

• Avoid gradients and photo printing: These often require simulated process or digital printing, which costs more than standard screen printing. Opt for flat colors and solid shapes.

Choose the Right Shirt Style and Supplier

• Select budget-friendly blank t-shirts: Gildan, Hanes, and Next Level offer quality options at lower price points. Premium brands like Bella+Canvas cost more but may be worth it for certain audiences.

• Compare multiple suppliers: Use online quote tools from companies like Custom Ink, Printful, RushOrderTees, or local screen printers. Request bulk quotes with your exact specs.

• Consider local vs. online printers: Local shops may offer lower shipping costs and easier communication, while online vendors often have better volume pricing.

Additional Tips for Maximum Savings

• Avoid rush shipping: Standard production and shipping are significantly cheaper.
• Buy in off-season: Order during slower months (e.g., winter) when printers have more capacity and may offer discounts.
• Ask about promo codes or package deals: Some vendors offer first-time buyer discounts or bundle pricing for multiple apparel types.

By combining smart ordering (hitting quantity breaks), simplifying your artwork, and choosing the right supplier, you can get high-quality custom t-shirts at the lowest possible price. Plan ahead, design efficiently, and always get multiple quotes to ensure the best deal.