Screen Printing vs. DTG vs. Heat Transfer: Best Option for Cheap Custom T-Shirts

| Feature | Screen Printing | DTG (Direct-to-Garment) | Heat Transfer (Vinyl/Inkjet) |
|—————————|————————————-|————————————-|————————————-|
| Best For | Large bulk orders (50+ shirts) | Small orders, detailed designs | Very small orders, simple designs |
| Cost per Shirt (Low Qty) | High (setup costs) | Medium to high | Low to medium |
| Cost per Shirt (High Qty)| Very low | Higher than screen printing | Medium to high |
| Setup Cost | High (screens, labor) | Low to none | None (except for cutting machine) |
| Design Complexity | Limited (few colors, simple art) | Excellent (full color, gradients) | Good (simple to moderate designs) |
| Color Accuracy | High (consistent batch colors) | High (photo-realistic) | Medium (can fade or peel) |
| Durability | Very high (long-lasting) | Medium (may fade after washes) | Low to medium (peeling over time) |
| Fabric Compatibility | Best on cotton; limited on blends | Works on cotton and light blends | Works on most fabrics (including polyester) |
| Production Speed | Fast for bulk, slow setup | Slow per shirt | Fast for small batches |
| Minimum Order | 10–50 shirts (due to setup) | 1 shirt | 1 shirt |
| Ideal Use Case | Bulk promotional shirts, logos | Custom one-offs, photos, art shirts | Names, numbers, small text, events |
| Upfront Equipment Cost | Very high ($1,000–$5,000+) | High ($10,000–$30,000) | Low ($200–$800 for basic setup) |
| DIY-Friendly | Difficult (requires skill/space) | Moderate (needs maintenance) | Very easy (home-friendly) |

Summary for Cheap Custom T-Shirts:

• Cheapest per shirt in bulk? → Screen Printing
• Cheapest for 1–10 shirts? → Heat Transfer or DTG (depending on design)
• Best quality for detailed designs? → DTG
• Most durable? → Screen Printing
• Easiest for beginners? → Heat Transfer

For truly cheap custom t-shirts, screen printing wins for large orders, while heat transfer is best for low quantities and simplicity. DTG offers a middle ground with great print quality but higher costs.

100% Cotton vs. Tri-blends vs. Polyester: Your Guide to Choosing Fabrics for Cheap Custom T-Shirts

When ordering custom t-shirts on a budget, the fabric you choose has a huge impact on comfort, durability, appearance, and cost. Here’s a breakdown of the three most common options—100% Cotton, Tri-blends, and Polyester—so you can pick the best one for your needs without breaking the bank.

100% Cotton: Classic Comfort at a Low Price

100% cotton t-shirts are the most traditional and widely available option for custom printing. They’re typically the cheapest choice, making them ideal for bulk orders like events, promotions, or team wear.

Pros:
– Affordable: Usually the lowest-cost fabric option.
– Soft and breathable: Feels comfortable against the skin, especially in warmer weather.
– Great for printing: Holds screen prints and direct-to-garment (DTG) designs well with vibrant results.
– Natural fiber: Biodegradable and eco-friendly (if organically sourced).

Cons:
– Prone to shrinking: Especially if not pre-shrunk; may require sizing up.
– Wrinkles easily: Less wrinkle-resistant than synthetic fabrics.
– Can fade or wear faster: With frequent washing, cotton may lose shape and color over time.

Best for: Budget-conscious orders where comfort and breathability are priorities—think casual giveaways, school events, or staff uniforms.

Tri-blends: Softness and Style on a Budget (Slightly Higher Cost)

Tri-blends typically consist of a mix of cotton, polyester, and rayon (e.g., 50% polyester, 25% cotton, 25% rayon). While slightly more expensive than 100% cotton, they offer a premium feel at a mid-range price.

Pros:
– Buttery soft feel: The rayon adds a smooth, lightweight texture.
– Minimal shrinking and fading: More durable than 100% cotton.
– Vintage look: Develops a worn-in, stylish appearance over time—great for trendy designs.
– Lightweight and drapey: Flattering fit that moves well with the body.

Cons:
– Higher cost than cotton: Not the cheapest option, but still affordable in bulk.
– Less breathable: Polyester content can make it warmer than pure cotton.
– Can pill over time: Especially with frequent washing or rough use.

Best for: Fashion-forward custom tees, boutique branding, or designs where a soft, vintage aesthetic is desired.

Polyester: Durable and Moisture-Wicking (Ideal for Performance)

Polyester is a synthetic fabric known for durability and moisture management. While less common for basic t-shirts, it’s popular for performance wear and sporty designs.

Pros:
– Highly durable: Resists shrinking, stretching, and wrinkles.
– Moisture-wicking: Pulls sweat away from the skin—great for active use.
– Colorfast: Holds bright colors well, especially with sublimation printing.
– Low maintenance: Dries quickly and requires minimal ironing.

Cons:
– Less breathable: Can feel hot or clammy in warm conditions.
– Less soft: Can have a plasticky or stiff feel compared to cotton or tri-blends.
– Not eco-friendly: Made from petroleum and not biodegradable.

Best for: Athletic teams, outdoor events, or promotional shirts meant for active use. Also ideal for all-over sublimation prints.

Which Should You Choose for Cheap Custom T-Shirts?

• Choose 100% Cotton if you want the lowest price, natural feel, and classic t-shirt comfort.
• Choose Tri-blends if you’re willing to spend a little more for a softer, more stylish look with better durability.
• Choose Polyester if the shirts will be used for sports, outdoor activities, or require moisture-wicking performance.

Pro Tip: Always order a sample before placing a bulk order. This lets you assess the fabric quality, fit, and print results in person—ensuring you get the best value for your budget.

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

Getting affordable custom t-shirts in bulk doesn’t mean sacrificing quality. With smart planning and the right strategies, you can save significantly on your order. Here’s how to get the best price on custom t-shirts—with key tips on bulk discounts and artwork preparation.

Leverage Bulk Discounts

One of the easiest ways to lower your cost per shirt is by ordering in bulk. Most screen printing and print-on-demand companies offer volume-based pricing, so the more you order, the cheaper each shirt becomes.

• Order 50+ shirts for the best rates: Many suppliers offer tiered pricing starting at 50 units. Jumping from 25 to 50 shirts can reduce your per-unit cost by 30–50%.
• Split sizes, not quantities: Stick to one design and distribute sizes (S, M, L, XL) within your bulk order. Mixing too many designs can increase setup fees.
• Avoid rush fees: Plan ahead and choose standard production times. Rush orders can increase costs by 20–50%.

Choose the Right Type of Shirt

The blank t-shirt you choose has a major impact on price.

• Opt for value-priced blanks: Brands like Gildan, Hanes, or Bella+Canvas offer affordable, high-quality options. 100% cotton is usually cheaper than blends or premium fabrics.
• Stick to one color: White or natural-colored shirts are typically less expensive than dyed ones.
• Compare per-unit costs across vendors: Use online quote tools from multiple suppliers to compare total costs, including shirts and printing.

Minimize Printing Complexity

The design directly affects printing costs.

• Use fewer colors: Screen printing charges per color. Stick to 1–3 colors to keep setup and ink costs low.
• Choose simple designs: Avoid gradients, fine details, or photorealistic images, which may require more expensive printing methods like DTG (Direct-to-Garment).
• Limit print locations: One print (front or back) is cheaper than multiple placements.

Prepare Your Artwork Properly

Well-prepared artwork saves time, reduces errors, and avoids extra fees.

• Use vector files (AI, EPS, SVG): These scale perfectly and are preferred by printers. Avoid low-resolution JPEGs or PNGs.
• Stick to high resolution (300 DPI): If submitting a raster image (like for DTG), ensure it’s 300 dots per inch at the intended print size.
• Outline fonts and embed images: This prevents text rendering issues when the printer opens your file.
• Provide a mockup: A clear visual helps avoid misunderstandings and costly reprints.

Get Multiple Quotes

Don’t settle for the first quote. Use online tools from reputable printers like:

• Custom Ink
• Printful
• T-Shirt Elephant
• VistaPrint
• Awkward Styles

Compare not just price, but also quality, turnaround time, and customer service. Some companies offer price-matching.

Take Advantage of Promotions

Look for seasonal sales, first-time customer discounts, or free shipping offers.

• Subscribe to newsletters from printing companies.
• Check for back-to-school, holiday, or end-of-season deals.
• Some vendors offer “free screens” or waived setup fees for large orders.

Final Tips for Maximum Savings

• Order slightly more than needed: It’s cheaper to add 5–10 extra shirts now than to reorder later.
• Coordinate group orders: Combine orders with friends, teams, or organizations to reach higher volume tiers.
• Review proofs carefully: Catch errors early to avoid reprint costs.

By following these tips on bulk ordering, design simplicity, and artwork prep, you can get high-quality custom t-shirts at the lowest possible price. Plan ahead, compare options, and communicate clearly with your printer for the best results.