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

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

Selecting the right fabric is crucial when creating custom t-shirts—it impacts comfort, durability, print quality, and overall feel. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends will help you make the best choice for your project.

100% Cotton T-Shirts

Pros:
– Soft, breathable, and comfortable against the skin
– Absorbs ink well, making it ideal for vibrant screen printing
– Natural fiber with a classic, timeless feel
– Biodegradable and eco-friendly option

Cons:
– More prone to shrinking (especially if not pre-shrunk)
– Can wrinkle easily and lose shape over time
– Less durable than blended fabrics under repeated wear and washing

Best For: Casual wear, promotional giveaways, eco-conscious brands, and designs with bold, detailed prints.

50/50 Blend T-Shirts (50% Cotton / 50% Polyester)

Pros:
– Resists shrinking and fading better than 100% cotton
– More durable and retains shape after multiple washes
– Lightweight and slightly more wrinkle-resistant
– Often more affordable than premium cotton or tri-blends

Cons:
– Slightly less soft than 100% cotton (though modern versions are much improved)
– Polyester can trap odors and is less breathable
– May pill over time with friction

Best For: Active environments, sports teams, workwear, and budget-friendly bulk orders where durability matters.

Tri-Blend T-Shirts (Typically 50% Polyester / 25% Cotton / 25% Rayon)

Pros:
– Ultra-soft, smooth, and drapes beautifully—often compared to vintage or luxury tees
– Excellent moisture-wicking and odor resistance (thanks to polyester)
– Minimal shrinkage and great shape retention
– Ideal for sublimation and soft-hand printing techniques

Cons:
– More expensive than cotton or 50/50 blends
– Not as breathable as 100% cotton due to high polyester content
– Can be more delicate; may snag or wear faster under rough use

Best For: Fashion-forward apparel, boutique brands, retail products, and soft, vintage-style prints.

Choosing the Right Fabric for Your Needs

• Comfort & Natural Feel: Choose 100% Cotton
• Durability & Budget-Friendly: Go with 50/50 Blend
• Luxury Softness & Style: Opt for Tri-Blend

Consider your audience, use case, printing method, and budget when deciding. Each fabric offers unique benefits—selecting the right one ensures your custom t-shirts look great, feel comfortable, and stand the test of time.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, support a cause, or outfit a team. By leveraging quantity breaks and optimizing your design process, you can significantly reduce your per-unit cost. Here’s how to get the best price on custom t-shirts.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) suppliers offer tiered pricing based on order volume—these are called quantity breaks. The more shirts you order, the lower the price per shirt.

• Typical Quantity Breaks:
  Common tiers include 12, 24, 50, 100, 250, 500, and 1000+ units. For example, the price per shirt might drop from $12 at 24 units to $6 at 250 units.

• Maximize Your Tier:
  Always aim to reach the next pricing tier. If 100 shirts cost $8 each but 250 cost $5 each, consider whether ordering 150 extra shirts (even if you don’t need them immediately) saves money long-term.

• Combine Orders:
  Partner with friends, teammates, or departments to consolidate orders and hit higher quantity brackets.

Choose the Right Printing Method

The print technique affects both cost and quality. Match your method to your design and budget.

• Screen Printing:
  Best for large orders (50+ units) with simple designs and few colors. Setup costs are high, but per-unit cost drops dramatically with volume.

• Direct-to-Garment (DTG):
  Ideal for complex, full-color designs or small batches. No setup fees, but higher per-shirt cost. Not cost-effective for large runs.

• Dye Sublimation:
  Great for all-over prints on polyester. Cost-effective for bulk orders of performance wear or activewear.

Optimize Your Artwork for Lower Costs

Your design choices directly impact printing expenses.

• Limit Print Colors:
  Each additional color in screen printing requires a separate screen and setup fee. Stick to 1–3 colors to minimize costs.

• Simplify Your Design:
  Avoid fine details or gradients that require advanced (and expensive) printing techniques. Bold, clean graphics print better and cheaper.

• Provide Print-Ready Files:
  Submit high-resolution (300 DPI) vector files (AI, EPS, or PDF) to avoid design correction fees. Include proper bleed and safe zones.

• Use Template Guides:
  Follow your supplier’s artwork template to prevent resizing or repositioning charges.

Select the Right T-Shirt Style and Brand

Not all blanks are created equal—choose wisely to balance quality and cost.

• Basic Cotton vs. Premium Blends:
  100% cotton is affordable and widely available. Blends (like cotton-polyester) may cost more but offer better durability and wrinkle resistance.

• Buy in Bulk from the Same Brand:
  Some suppliers offer discounts for ordering all shirts from one brand or product line.

• Consider Weight and Fit:
  Lightweight shirts (e.2 4.5 oz) are cheaper than heavyweight options. Standard fits are less expensive than fashion cuts.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote you receive.

• Compare 3–5 Suppliers:
  Use online quote tools from reputable printers to compare pricing, turnaround time, and shipping.

• Ask About Discounts:
  Inquire about promotions, nonprofit discounts, or first-time customer deals.

• Negotiate for Large Orders:
  If ordering 500+ units, ask for a custom quote—you may get additional savings or free design services.

Plan Ahead to Avoid Rush Fees

Rush orders can increase costs by 25–50%.

• Order Early:
  Give yourself 2–4 weeks for production and shipping.

• Schedule Seasonally:
  Avoid peak times (back-to-school, holidays) when demand (and prices) are higher.

By leveraging bulk quantity breaks, simplifying your artwork, and choosing the right materials and methods, you can create high-quality custom t-shirts at a fraction of the cost. Plan smart, design efficiently, and always compare your options.