Comparison of Custom T-Shirt Printing Methods

Guide to Choosing Fabrics for Custom Business T-Shirts: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

When ordering custom business t-shirts for your team, employees, or promotional events, selecting the right fabric is crucial. The material impacts comfort, durability, appearance, and how well your logo or design prints. Here’s a breakdown of the three most popular fabric choices to help you make an informed decision.

100% Cotton

Pros:
– Soft and Breathable: Natural cotton fibers provide excellent comfort, especially in warmer climates or during physical activity.
– Classic Feel: Offers a traditional, familiar t-shirt feel that many people prefer.
– Eco-Friendly Option: Biodegradable and sustainable, especially if you choose organic cotton.
– Great for Screen Printing: Holds ink well, resulting in vibrant, long-lasting prints.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: More likely to wear out, pill, or lose shape over time with frequent washing.
– Wrinkles Easily: Requires ironing or steaming to maintain a crisp, professional look.

Best For: Casual work environments, eco-conscious brands, or when a natural, soft feel is a top priority.

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

Pros:
– Durable and Long-Lasting: Polyester adds strength, helping the shirt resist shrinking, pilling, and stretching.
– Low Maintenance: Wrinkle-resistant and retains its shape well after multiple washes.
– Affordable: Often more budget-friendly than tri-blends, offering a good balance of quality and cost.
– Good Printability: Works well with screen printing and direct-to-garment (DTG) methods.

Cons:
– Less Breathable: Polyester traps heat, which can make the shirt feel warmer in hot weather.
– Slightly Stiffer Feel: Not as soft as 100% cotton or tri-blends, especially when new.

Best For: High-use environments, promotional giveaways, or businesses looking for a durable, economical option with a professional appearance.

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

Pros:
– Ultra-Soft and Lightweight: Offers a luxurious, vintage-style feel that feels broken-in from the first wear.
– Excellent Drape: Flatters the body and moves comfortably, ideal for a modern, stylish look.
– Wrinkle-Resistant: Maintains a clean appearance with minimal care.
– Great for DTG Printing: Produces soft-hand prints with a retro aesthetic.

Cons:
– Less Durable: More delicate than 100% cotton or 50/50 blends—may wear faster with heavy use or frequent washing.
– Higher Cost: Typically more expensive due to the premium feel and materials.
– Not Ideal for Heavy Use: Better suited for light-duty wear or fashion-forward branding.

Best For: Creative agencies, tech startups, or lifestyle brands that prioritize style, comfort, and a modern aesthetic.

Final Tips for Choosing the Right Fabric

• Consider the Use Case: Will employees wear these daily, or are they for special events? High wear calls for durability (50/50 blend), while image-focused branding may benefit from tri-blend softness.
• Think About Climate: Cotton breathes well in heat; polyester blends offer moisture-wicking benefits but may feel warmer.
• Match Fabric to Print Method: Screen printing works on all three, but tri-blends shine with DTG for soft, detailed designs.
• Sample First: Order samples of each fabric to feel the difference and assess print quality before bulk ordering.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can choose the ideal fabric that reflects your brand identity and meets the practical needs of your team.

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

Ordering custom business T-shirts in bulk can be a cost-effective way to promote your brand, unify your team, or market your company. However, to secure the best possible price—without sacrificing quality—it’s important to understand bulk pricing structures and how to prepare your artwork efficiently. Follow these expert tips to maximize savings.

Understand Bulk Quantity Breaks

Most screen printing and embroidery companies use tiered pricing, meaning the more shirts you order, the lower the cost per unit. These are called “quantity breaks.”

• Common Quantity Tiers:
  Typical quantity breaks start at 12, 24, 48, 72, 144, 288, and 576 units. For example:
• 12–23 shirts: $15 each
• 24–47 shirts: $12 each
• 48–71 shirts: $10 each
• 72–143 shirts: $8 each

• 144+ shirts: $6 each

• Order Just Above the Threshold:
  If you need 60 shirts, ordering 72 (the next break point) could save you significantly per shirt—potentially cutting your total cost by hundreds of dollars.

• Consolidate Orders:
  If multiple departments need shirts, combine orders to reach higher volume tiers. Even better, plan annual needs in one large order to reduce per-unit costs and setup fees.

Choose the Right Shirt Style and Brand

Not all T-shirts are created equal—and price varies widely based on brand, fabric, and quality.

• Opt for Budget-Friendly Blends:
  100% cotton is classic, but cotton-polyester blends (like 50/50) are often cheaper, more durable, and resist shrinking. They also print well.

• Stick to One or Two Styles:
  Mixing multiple shirt styles increases setup time and labor. Choosing one base model simplifies production and reduces costs.

• Buy In-Stock Colors:
  Standard colors like black, white, navy, and gray are cheaper and faster to ship than special-order or fashion colors.

Simplify Your Artwork to Lower Setup Costs

Artwork complexity directly affects printing costs, especially in screen printing where each color requires a separate screen.

• Limit the Number of Print Colors:
  A one- or two-color design is significantly cheaper than a full-color or photographic print. Each added color increases screen setup fees and printing time.

• Use Vector Art:
  Provide your logo in vector format (AI, EPS, or SVG). Vector files scale perfectly and ensure crisp prints—avoid blurry logos from low-resolution JPEGs or PNGs.

• Keep the Design Simple:
  Minimalist designs are not only trendy but also cost-effective. Avoid gradients, shading, and excessive detail that require advanced printing techniques.

• Use One Print Location:
  Printing on just the front or back is cheaper than front and back. If branding both sides is essential, consider a small logo on one side and a larger design on the other to minimize ink and screens.

Get Multiple Quotes and Negotiate

Never settle for the first quote you receive.

• Compare at Least 3–5 Vendors:
  Use online printing platforms (like Custom Ink, Printful, or local screen printers) to compare pricing, turnaround time, and customer reviews.

• Ask About Hidden Fees:
  Clarify costs for setup, screens, art corrections, and shipping. Some vendors offer free setup for bulk orders—always ask.

• Leverage Long-Term Relationships:
  If you plan repeat orders, mention it. Vendors may offer discounts or loyalty pricing for future business.

Final Tips for Maximum Savings

• Order Off-Season:
  Demand for custom apparel peaks in spring and summer. Ordering in fall or winter may yield better deals.

• Avoid Rush Fees:
  Plan ahead and allow 2–3 weeks for production and shipping. Rush orders can double your costs.

• Request a Physical Sample:
  Before committing to a large order, get a sample shirt printed. This ensures quality and color accuracy—saving money on costly reprints.

By leveraging bulk quantity breaks, simplifying your artwork, and choosing the right materials and vendors, you can get high-quality custom business T-shirts at the best possible price. Smart planning today leads to big savings tomorrow.