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

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

When ordering custom t-shirts on a budget, fabric choice plays a huge role in both cost and quality. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you balance affordability with comfort and durability. Here’s a breakdown to help you decide.

100% Cotton: Classic Comfort at a Lower Price

100% cotton t-shirts are the most common and affordable option for cheap custom printing.

• Pros:
• Soft, breathable, and comfortable—especially in warmer weather.
• Highly absorbent, making it ideal for vibrant screen printing.
• Natural fiber, which many customers prefer.

• Widely available at low cost.

• Cons:

• Prone to shrinking (usually 5–7%) if not pre-shrunk.
• Less durable over time—can pill, fade, or lose shape after repeated washes.
• Wrinkles easily and may feel heavier than blended fabrics.

Best for: Budget-conscious bulk orders (e.g., event shirts, promotional giveaways) where breathability and print quality matter more than long-term wear.

50/50 Blend: The Balanced Budget Choice

A 50/50 blend combines 50% cotton and 50% polyester, offering a middle ground between comfort and durability.

• Pros:
• Resists shrinking and wrinkling better than 100% cotton.
• More durable and retains shape over time.
• Slightly lighter and dries faster due to polyester content.

• Often priced only slightly higher than 100% cotton, making it a cost-effective upgrade.

• Cons:

• Less breathable than pure cotton—can feel warmer.
• May not absorb ink as well for certain prints (though modern blends work fine with most printing methods).
• Slight synthetic feel compared to natural cotton.

Best for: Workwear, school events, or active use where durability and minimal shrinkage are priorities—without breaking the budget.

Tri-Blends: Softness and Style (Slightly Higher Cost)

Tri-blend fabrics typically mix cotton, polyester, and rayon (e.g., 50% poly, 25% cotton, 25% rayon). While slightly more expensive, they offer premium comfort.

• Pros:
• Exceptionally soft, with a lightweight, vintage feel.
• Drapes beautifully—great for fitted or fashion-forward styles.
• Resists shrinking and holds color well.

• Moisture-wicking and quick-drying.

• Cons:

• Higher cost than cotton or 50/50 blends.
• Less durable under heavy use—may pill or wear faster with rough handling.
• Not ideal for heavy-duty work environments.

Best for: Boutique brands, fashion-focused merch, or premium giveaways where comfort and aesthetics matter. May not be the cheapest option, but offers great value for perceived quality.

Final Tips for Choosing on a Budget

• For the Lowest Cost: Choose 100% cotton—especially if pre-shrunk. It’s the go-to for cheap, high-volume orders.
• For Longevity and Low Maintenance: Go with a 50/50 blend—it offers better wear resistance at a small price increase.
• For Premium Feel on a Slight Budget Bump: Consider tri-blends for standout quality in fashion or lifestyle contexts.

Always request fabric swatches from your supplier and consider your audience, use case, and print method when making your choice. Even on a budget, the right fabric can make your custom shirts feel like a million bucks.

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

Ordering custom t-shirts in bulk is a cost-effective way to promote your brand, team, or event—but getting the best price requires strategy. Here’s how to maximize savings through smart bulk ordering and artwork preparation.

Leverage Bulk Quantity Breaks for Lower Per-Unit Costs

Most screen printing and apparel companies offer tiered pricing based on order size. Understanding and using quantity breaks is key to reducing your cost per shirt.

• Know the standard tiers: Common quantity breaks are 25, 50, 75, 100, 250, and 500 units. Prices drop significantly at each threshold—e.g., ordering 100 shirts instead of 75 can save $1–$3 per shirt.
• Aim for the next break point: If you’re close to a tier (e.g., 95 shirts), consider increasing your order to 100. The total cost may only rise slightly, but the per-unit price drops substantially.
• Split sizes wisely: Stay within one design and color family across sizes to maintain eligibility for bulk pricing. Mixing too many colors or styles may disqualify you from volume discounts.
• Consolidate orders: Combine multiple events, teams, or departments into one large order to hit higher quantity tiers and reduce setup fees.

Optimize Your Artwork to Cut Printing Costs

The complexity of your design directly impacts printing expenses. Simple, well-prepared artwork saves money—especially with screen printing.

• Limit print colors: Each ink color requires a separate screen and setup. Stick to 1–3 colors to minimize costs. Use simulated process or halftones only when necessary.
• Use vector artwork: Supply logos and graphics in vector formats (AI, EPS, SVG) for crisp scaling and easier separation. Avoid low-res JPEGs or PNGs.
• Simplify your design: Remove fine details, gradients, and small text that require complex screens or embroidery. Bold, clean graphics are cheaper to reproduce.
• Choose the right print method:
• Screen printing is cheapest for large runs with few colors.
• DTG (Direct-to-Garment) works well for small batches or full-color designs but costs more per unit.
• Heat transfer is ideal for very small orders but less durable.
• Provide a print-ready file: Include a high-resolution (300 DPI), outlined text, and a clear mockup. This reduces back-and-forth with the printer and prevents costly errors.

By combining strategic bulk ordering with streamlined artwork, you can significantly reduce the cost of custom t-shirts without sacrificing quality. Always request quotes from multiple vendors and ask about their quantity discounts and artwork requirements upfront.