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

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

When ordering custom T-shirts in bulk, selecting the right fabric is one of the most important decisions you’ll make. The material affects comfort, durability, print quality, cost, and how your shirts look and feel over time. Here’s a detailed comparison of the three most popular fabric choices: 100% Cotton, 50/50 Cotton-Polyester Blend, and Tri-Blends.

100% Cotton: Classic Comfort and Softness

Pros:
– Ultra-Soft Feel: Offers a natural, breathable, and comfortable hand feel that many people prefer.
– Excellent Printability: Holds vibrant screen prints and direct-to-garment (DTG) designs exceptionally well.
– Eco-Friendly: Biodegradable and made from a renewable resource, appealing to environmentally conscious buyers.
– Great for Warmer Climates: Highly breathable, allowing air circulation to keep wearers cool.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk; requires proper washing care.
– Less Durable: Can wear out faster with frequent washing and may pill over time.
– Wrinkles Easily: Tends to crease and wrinkle more than blended fabrics.
– Absorbs Moisture: While breathable, it holds onto sweat, which can feel damp during physical activity.

Best For: Casual wear, promotional events, retail apparel, and customers who value softness and natural fibers.

50/50 Cotton-Polyester Blend: Durability Meets Comfort

Pros:
– Reduced Shrinkage: The polyester content helps minimize shrinkage, maintaining size and shape.
– More Durable: Resists pilling and withstands repeated washing better than 100% cotton.
– Wrinkle-Resistant: Holds its shape and looks fresher longer, ideal for workwear or uniforms.
– Moisture-Wicking: Polyester helps draw moisture away from the skin, making it a better choice for active use.

Cons:
– Slightly Less Soft: Can feel slightly rougher than 100% cotton, though modern versions are much improved.
– Less Breathable: Not as airy as pure cotton, which may be less comfortable in hot weather.
– Print Quality Variability: May require specialized inks for optimal print results, especially with DTG.

Best For: Corporate giveaways, team uniforms, school events, and active environments where durability and consistency matter.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon): Premium Softness and Drape

Pros:
– Buttery Soft Texture: The rayon adds a luxurious, silky feel that’s highly desirable.
– Excellent Drape: Flatters the body with a smooth, slightly fitted look—great for fashion-forward designs.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic content.
– Vintage Aesthetic: Often has a slightly heathered or worn-in look that appeals to modern style trends.

Cons:
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Less Durable: Rayon can weaken when wet and may wear faster with heavy use.
– Care Sensitivity: Requires gentle washing and drying to maintain quality.
– Print Challenges: Requires precise heat and pressure during printing to avoid scorching or ink bleed.

Best For: Fashion brands, boutique orders, gift items, or any bulk order where a premium look and feel are priorities.

Which Should You Choose?

• Choose 100% Cotton if you want a natural, soft, eco-friendly option ideal for everyday wear and vibrant printing.
• Opt for 50/50 Blend when durability, cost-efficiency, and low maintenance are key—perfect for high-volume use.
• Go with Tri-Blend for a high-end, stylish product that feels luxurious and drapes beautifully, ideal for fashion-conscious audiences.

Consider your audience, use case, budget, and desired brand image when making your choice. Testing samples before placing a large bulk order is always recommended to ensure the fabric meets your expectations.

How to Get the Best Price for Custom Bulk T-Shirts

Ordering custom bulk T-shirts doesn’t have to break the bank. With smart planning and strategic decisions, you can significantly reduce costs while maintaining quality. Here’s how to get the best price for your bulk T-shirt order, including tips on quantity breaks and artwork optimization.

Leverage Quantity Breaks for Lower Per-Unit Costs

One of the most effective ways to save money is by taking advantage of quantity breaks—price reductions offered when you order larger volumes. Here’s how to use them:

• Understand the Pricing Tiers: Most suppliers offer tiered pricing (e.g., 50–99 units, 100–249, 250+, etc.). Always ask for a detailed price breakdown. Often, jumping to the next tier (e.g., from 99 to 100 shirts) results in a lower per-unit cost.

• Order Just Above the Threshold: If 100 shirts cost $10 each but 250 cost $7, consider whether increasing your order to 250 provides long-term value—even if you don’t need all shirts immediately.

• Collaborate with Others: If you’re near a pricing threshold, partner with another team, club, or event to combine orders and qualify for lower rates.

Choose the Right T-Shirt Style and Brand

• Opt for Budget-Friendly Blends: 100% cotton is popular, but cotton-polyester blends are often cheaper and more durable. They also resist shrinking and wrinkling.

• Stick to One Style and Color: Mixing shirt styles, colors, or brands increases setup and printing costs. Choosing one base model streamlines production and reduces labor.

Minimize Print Complexity to Reduce Artwork Costs

Artwork complexity directly impacts printing costs. Follow these tips to keep costs low:

• Limit Print Colors: Each additional color increases screen setup fees. Stick to 1–2 colors for the best pricing, especially with screen printing.

• Use Simpler Designs: Avoid gradients, fine details, or photorealistic images—they require more ink and advanced printing techniques (like DTG), which are costlier.

• Size Matters: Smaller prints use less ink and are faster to apply. Standard print areas (like left chest or center back) are often cheaper than full sleeves or oversized designs.

Prepare Print-Ready Artwork to Avoid Fees

Many vendors charge extra for artwork setup or design services. Save money by providing ready-to-print files:

• Submit High-Resolution Files: Use vector formats (AI, EPS, SVG) or high-DPI (300+) PNGs.

• Specify Pantone (PMS) Colors: This ensures color accuracy and reduces back-and-forth adjustments.

• Follow the Printer’s Template: Use provided design guides for bleed, safe zones, and placement to avoid rework.

Compare Multiple Vendors and Negotiate

• Get Quotes from 3–5 Suppliers: Prices vary widely. Use online quote tools or request custom bids.

• Ask About Hidden Fees: Inquire about setup fees, screen charges, and shipping costs upfront to compare true total costs.

• Negotiate for Repeat Business: If you plan future orders, mention it—many suppliers offer discounts for loyalty or bulk commitments.

Plan Ahead to Avoid Rush Fees

Rush orders can increase costs by 25–50%. To avoid this:

• Place Orders Early: Allow 2–4 weeks for production and shipping.

• Schedule Around Holidays: Lead times increase during peak seasons (e.g., back-to-school, holidays).

By combining smart quantity decisions, simplified artwork, and vendor negotiation, you can get high-quality custom T-shirts at the lowest possible price—perfect for events, promotions, or teams.