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

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

When ordering custom t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and how well your design prints. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you make the best decision for your needs.

100% Cotton: Classic Comfort and Softness

100% cotton t-shirts are a timeless favorite for their natural feel and breathability.

• Pros:
• Incredibly soft and comfortable against the skin
• Highly breathable, ideal for warm weather or active wear
• Absorbs ink well, resulting in vibrant screen printing

• Biodegradable and eco-friendly (if organically sourced)

• Cons:

• Prone to shrinking (especially if not pre-shrunk)
• Less durable over time—can pill or wear faster with frequent washing
• Wrinkles easily and may lose shape after repeated use

Best for: Everyday wear, events in warm climates, or when a natural, soft hand-feel is a top priority.

50/50 Blend: The Best of Both Worlds

A 50/50 blend combines cotton and polyester, offering a balanced mix of comfort and performance.

• Pros:
• Resists shrinking and wrinkling better than 100% cotton
• More durable and long-lasting
• Slightly lighter weight with improved moisture-wicking

• Cost-effective and great for promotional apparel

• Cons:

• Slightly less soft than 100% cotton (though modern versions are much improved)
• May not absorb ink as deeply, affecting print vibrancy slightly
• Polyester content can feel less breathable in hot weather

Best for: Workwear, giveaways, school events, or when durability and low maintenance are important.

Tri-Blends: Softness Meets Performance

Tri-blend fabrics typically mix cotton, polyester, and rayon (often in a 50/25/25 ratio), creating a lightweight, smooth, and premium-feeling fabric.

• Pros:
• Exceptionally soft with a silky, vintage-like drape
• Excellent breathability and moisture management
• Minimal shrinkage and great shape retention

• Offers a modern, fashion-forward look

• Cons:

• More expensive than cotton or 50/50 blends
• Can be more delicate—may require gentler washing
• Some tri-blends may pill over time with heavy use

Best for: Fashion-forward custom tees, boutique apparel, or when you want a high-end, comfortable feel.

Choosing the Right Fabric for Your Custom T-Shirt

Consider these factors when deciding:
– Use Case: Is it for a concert, corporate event, retail sale, or daily wear?
– Climate: Hot and humid? Go breathable (cotton or tri-blend). Active use? Consider moisture-wicking (50/50 or tri-blend).
– Budget: 50/50 blends often offer the best value. Tri-blends are premium-priced.
– Print Quality: All work well with modern printing techniques, but cotton absorbs ink best for classic screen prints.

Ultimately, your choice depends on balancing comfort, durability, cost, and aesthetics. Test swatches when possible to feel the difference firsthand before placing a large order.

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

Purchasing custom t-shirts in bulk can be a cost-effective way to promote your brand, organize events, or sell merchandise. To maximize savings and ensure high-quality results, follow these key strategies focused on bulk pricing and artwork optimization.

Leverage Bulk Quantity Breaks

One of the most effective ways to reduce the cost per unit is by ordering in larger quantities. Most screen printing and embroidery companies offer significant price breaks at specific volume thresholds.

• Know the Common Quantity Tiers: Typical bulk breaks occur at 50, 100, 250, 500, and 1,000+ units. Ordering just above a threshold (e.g., 101 instead of 99) often reduces the per-unit cost dramatically.
• Compare Unit Prices: Get quotes for multiple quantities to find the “sweet spot” where price per shirt drops substantially.
• Split Sizes, Not Quantities: Distribute your order across different sizes (S, M, L, XL) without dropping below the bulk tier to maintain lower pricing.
• Plan Ahead: If you’re unsure about future needs, it’s often cheaper to order more now and store extras than to reorder small batches later.

Choose the Right Printing Method

The printing technique significantly impacts both cost and quality:

• Screen Printing: Most economical for bulk orders (50+ units) with simple designs and few colors. Each additional color increases setup costs.
• Digital Printing (DTG): Better for complex, full-color designs or small runs. Less cost-effective at scale.
• Heat Transfer: Suitable for detailed artwork but less durable and pricier for large quantities.
• Embroidery: Ideal for logos on polos or hoodies but more expensive; best reserved for premium branding.

Optimize Your Artwork for Lower Costs

Smart design choices can reduce production complexity and save money:

• Limit the Number of Colors: Each ink color requires a separate screen and setup. Stick to 1–3 colors to minimize costs.
• Simplify the Design: Clean, bold graphics with minimal detail reduce printing time and errors.
• Use Vector Files: Provide artwork in vector format (AI, EPS, or SVG) to ensure crisp printing at any size. Avoid pixelated images (JPEG, PNG) unless high-resolution.
• Standard Print Locations: Chest prints are cheaper than full-back or sleeve designs. Stick to one or two standard locations unless necessary.
• Repurpose Artwork: Use the same design across multiple products (e.g., t-shirts, tote bags) to save on setup fees.

Get Multiple Quotes & Negotiate

• Shop Around: Request quotes from at least 3–5 reputable suppliers. Compare not just price, but turnaround time, quality, and customer service.
• Ask About Discounts: Inquire about first-time buyer discounts, seasonal promotions, or loyalty programs.
• Bundle Services: Some vendors offer reduced rates if you’re also ordering hats, hoodies, or other apparel.
• Negotiate for Larger Orders: If placing a very large order (500+ units), ask for a custom discount or free setup fees.

Final Tips for Best Value

• Choose Mid-Weight, Basic Fabrics: 100% cotton or cotton blends (e.g., 50/50) offer a good balance of comfort, durability, and price.
• Avoid Rush Fees: Plan ahead and allow 2–3 weeks for production to avoid expedited charges.
• Request a Physical Sample: Confirm print quality and fabric feel before placing a large order.

By combining smart bulk ordering, efficient artwork, and strategic vendor selection, you can achieve professional-quality custom t-shirts at the best possible price.