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

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

When ordering custom t-shirts on a budget, the fabric choice plays a huge role in comfort, durability, and overall look. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you make a smart, cost-effective decision without sacrificing quality.

100% Cotton: Soft and Classic

100% cotton t-shirts are a timeless favorite known for their soft feel and natural breathability. Made entirely from cotton fibers, these shirts are comfortable against the skin and ideal for warm weather. They absorb moisture well, making them a go-to for everyday wear or promotional events.

Pros:
– Soft, natural feel
– Breathable and comfortable
– Excellent for printing (especially screen printing)
– Biodegradable and eco-friendly

Cons:
– Prone to shrinking (especially if not pre-shrunk)
– Can wrinkle easily
– Less durable over time; may thin or pill with frequent washes
– Often more expensive than blended fabrics

Best for: Classic tees, eco-conscious brands, screen-printed designs, casual wear

50/50 Blend: The Budget-Friendly Workhorse

A 50/50 blend combines equal parts cotton and polyester, offering a balance of comfort and durability. This blend is popular for custom t-shirts because it resists shrinking and holds up well to repeated washing—ideal for uniforms, events, or giveaways.

Pros:
– Resists shrinking and wrinkling
– More durable than 100% cotton
– Affordable and widely available
– Holds color well for prints

Cons:
– Slightly less breathable than pure cotton
– Can feel less soft or slightly synthetic
– May retain odors more than cotton

Best for: High-volume orders, promotional giveaways, workwear, events with heavy use

Tri-Blends: Softness Meets Durability

Tri-blend fabrics typically mix polyester, cotton, and rayon (often in a 50/25/25 ratio). This combination creates a luxuriously soft, lightweight shirt with a slight drape and vintage feel. Tri-blends are known for their smooth texture and excellent printability.

Pros:
– Exceptionally soft and comfortable
– Minimal shrinking and excellent shape retention
– Unique, slightly heathered appearance
– Great drape and modern look

Cons:
– Usually more expensive than cotton or 50/50 blends
– Can be less breathable due to higher polyester content
– May require special care (gentler wash cycles)

Best for: Fashion-forward designs, retail sales, premium-feel custom shirts, soft-hand screen printing or DTG

Making the Right Choice on a Budget

For the cheapest custom t-shirts, 50/50 blends often provide the best value—offering durability, printability, and lower cost. If softness is a top priority and you can stretch the budget slightly, tri-blends deliver a premium feel. For a classic, natural option, 100% cotton works well but may cost more and require pre-shrunk versions to avoid issues.

Tip: Always request fabric samples before placing a large order. This helps you assess comfort, weight, and print quality firsthand—ensuring your custom shirts meet expectations without overspending.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, team, or event. By leveraging quantity breaks and smart artwork practices, you can significantly reduce your per-unit cost. Here’s how to get the best price possible.

Understand Bulk Quantity Breaks

Most screen printers and online print-on-demand services offer tiered pricing based on order size—known as quantity breaks. The larger your order, the lower the price per shirt.

• Know the Thresholds: Common quantity breaks occur at 12, 24, 50, 100, 250, and 500 units. Ordering just above a break (e.g., 101 instead of 100) can drastically reduce your cost per item.
• Compare Quotes: Request quotes from multiple suppliers for different quantities. Some companies offer steeper discounts at higher volumes.
• Order More, Save More: If you anticipate future needs, consider ordering extra shirts now to stay above a quantity break and save money.

Choose the Right T-Shirt Style and Brand

Not all blanks are created equal. Simpler, value-priced garments (like Gildan 5000 or Hanes Beefy-T) are much cheaper than premium brands (like Bella+Canvas or Next Level).

• Opt for Basic Cotton: 100% cotton tees are typically the most affordable and widely available.
• Stick to Standard Sizes: Avoid specialty sizes (like 5XL) or colors, which may cost more or require longer lead times.
• Use In-Stock Colors: Choose popular shirt colors (heather grey, navy, black, white) to avoid dye surcharges or extended production times.

Simplify Your Design for Lower Printing Costs

Printing complexity directly affects your price. Fewer colors, smaller print areas, and simpler designs equal lower costs.

• Limit Ink Colors: Each additional color requires a separate screen and setup fee. Stick to 1–3 colors whenever possible.
• Use One-Sided Printing: Printing on the front only is cheaper than adding a back or sleeve design.
• Optimize Print Size: Larger prints use more ink and may increase costs. Keep your design within a standard print area (e.g., 10” x 12”).

Prepare Print-Ready Artwork

Suppliers often charge extra for artwork setup or file corrections. Providing clean, print-ready artwork saves time and money.

• Use Vector Files: Supply your logo or design in vector format (AI, EPS, or SVG) for crisp, scalable printing.
• High-Resolution Rasters: If using PNG or JPG, ensure a resolution of at least 300 DPI at the actual print size.
• Specify Pantone (PMS) Colors: This ensures color accuracy and avoids guesswork, reducing revision costs.

Time Your Order Strategically

Production schedules and promotions can impact pricing.

• Avoid Rush Fees: Plan ahead to use standard production times (usually 7–14 days). Rush orders can double printing costs.
• Watch for Sales and Promotions: Many suppliers offer seasonal discounts, first-time customer deals, or free shipping on bulk orders.
• Order Off-Peak: Demand spikes around holidays and back-to-school season. Ordering in late winter or early spring may yield better pricing.

Bundle Services and Negotiate

Leverage your order size to get added value.

• Ask About Free Setup: Some suppliers waive screen setup fees for large orders (e.g., 100+ shirts).
• Request Free Samples: Get a physical proof before mass production to avoid costly reprints due to errors.
• Negotiate: For very large orders (500+), don’t hesitate to ask for a custom quote or discount.

By combining smart ordering practices with design efficiency, you can achieve high-quality custom t-shirts at the lowest possible price—perfect for startups, events, and growing brands.