Comparison of Custom T-Shirt Printing Methods for Budget-Friendly Options

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

When ordering custom t-shirts on a budget, fabric choice plays a huge role in both cost and quality. The three most common options—100% cotton, 50/50 blend, and tri-blend—each offer distinct advantages and trade-offs. Here’s a breakdown to help you pick the best one for your needs.

100% Cotton

Pros:
– Soft and Breathable: Pure cotton feels natural against the skin and allows good airflow, making it comfortable in warm weather.
– Eco-Friendly (Often): Cotton is biodegradable and renewable, especially if organic.
– Great for Printing: Holds ink well, especially with screen printing, resulting in vibrant, crisp designs.

Cons:
– Prone to Shrinkage: Can shrink up to 5–7% after washing, especially if not pre-shrunk.
– Less Durable Over Time: More susceptible to pilling and wear with frequent washing.
– Wrinkles Easily: Requires ironing for a polished look.

Best For: Budget-friendly basics, promotional giveaways, or events where comfort and print quality are priorities. Look for “ring-spun” cotton for a softer, more durable option.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Affordable & Durable: Combines the softness of cotton with the strength and resilience of polyester.
– Reduced Shrinkage: Much more stable in the wash than 100% cotton.
– Wrinkle-Resistant: Holds its shape and looks neater longer.

Cons:
– Less Breathable: Polyester traps heat, making it less comfortable in hot conditions.
– Slight Sheen: May have a subtle synthetic look compared to pure cotton.
– Fuzzing Over Time: Can develop small pills with heavy use.

Best For: High-volume orders like corporate events, school spirit wear, or staff uniforms where durability and cost-efficiency matter.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Pros:
– Ultra-Soft Feel: Often described as having a “vintage” or “buttery” hand-feel.
– Excellent Drape: Flatters the body with a smooth, lightweight flow.
– Color-Rich Prints: Rayon enhances color vibrancy, especially with dye-sublimation.

Cons:
– Higher Cost: Generally more expensive than 100% cotton or 50/50 blends.
– Less Durable: More delicate; can stretch or tear more easily.
– Shrinks with Heat: Sensitive to high heat drying—requires cold wash and low tumble dry.

Best For: Premium-feeling custom tees, boutique brands, or fashion-forward designs where softness and drape outweigh durability concerns.

Final Tips for Choosing

• Budget First: 50/50 blends often offer the best balance of cost, durability, and comfort.
• Intended Use: Choose durability (50/50) for workwear, softness (tri-blend) for fashion, and breathability (100% cotton) for casual or outdoor use.
• Print Method Matters: All three work well with screen printing, but tri-blends shine with soft-hand or all-over prints.
• Check Fabric Weight: Measured in ounces per square yard (e.g., 4.5 oz vs. 6.1 oz). Lighter weights cost less but feel thinner.

By matching your fabric to your priorities—cost, comfort, durability, or style—you can get high-impact custom t-shirts without overspending.

How to Get the Best Price on Custom T-Shirts in Bulk

Ordering custom t-shirts in bulk is a cost-effective way to promote your brand, organize events, or sell merchandise. To ensure you get the best price without sacrificing quality, follow these key strategies focused on quantity breaks and artwork optimization.

Leverage Bulk Quantity Breaks

One of the most effective ways to lower your per-unit cost is by taking full advantage of volume pricing tiers offered by suppliers.

• Order in Larger Quantities: Most screen printers and online manufacturers offer significant price reductions at higher volume thresholds—commonly at 50, 100, 250, and 500+ units. For example, ordering 250 shirts might cost $5 each, while 500 could drop the price to $3.50 each.
• Consolidate Orders: If you’re part of an organization or event team, combine multiple small orders into one large purchase to qualify for better pricing.
• Split Sizes and Colors Strategically: Many suppliers base pricing on total quantity, regardless of size or color variations, as long as the design remains the same. Ordering different sizes or colors within the same design still counts toward your bulk discount.
• Compare Multiple Vendors: Use quote tools from platforms like Custom Ink, Printful, or local screen printers to compare how their pricing tiers stack up. Some offer steeper discounts at lower volumes, while others shine at 1,000+ units.

Optimize Your Artwork for Lower Printing Costs

The design complexity directly impacts production costs, especially for screen printing. Simplifying your artwork can significantly reduce your price per shirt.

• Limit the Number of Print Colors: Each additional color requires a separate screen and setup fee. Stick to 1–3 colors to minimize costs. For example, a one-color design is much cheaper than a full-color design.
• Use Vector Artwork: Supply your logo or design in vector format (e.g., .AI, .EPS, or .SVG). This ensures crisp printing at any size and avoids extra fees for artwork redrawing.
• Avoid Photographic or Gradient Designs: These often require simulated process printing or direct-to-garment (DTG) methods, which are more expensive. Opt for flat colors and solid shapes when possible.
• Simplify Design Details: Reduce fine lines, small text, and intricate elements that may not print well or could require expensive techniques.
• Choose the Right Printing Method: For bulk orders with simple designs, screen printing is usually the most affordable. For complex, multi-color designs in smaller volumes, DTG might be better—but it’s pricier at scale.

By combining smart bulk ordering with print-friendly artwork, you can significantly reduce your custom t-shirt costs while maintaining professional quality. Plan ahead, request samples, and always get multiple quotes to ensure you’re getting the best deal.