Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

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

Selecting the right fabric for your custom company t-shirts is crucial—it affects comfort, durability, appearance, and overall employee satisfaction. With options like 100% cotton, 50/50 blends, and tri-blends, each material offers distinct advantages and trade-offs. Here’s a breakdown to help you make the best choice for your team and brand.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and breathable: Ideal for warmer climates or active environments.
– Natural feel: Preferred by many for its soft, familiar texture.
– Excellent printability: Holds vibrant, crisp designs—especially with screen printing.
– Eco-friendly appeal: Biodegradable and renewable (especially if organic cotton is used).

Cons:
– Prone to shrinking: May shrink 3–5% after washing if not pre-shrunk.
– Less durable: Can wear out faster with frequent washing and heavy use.
– Wrinkles easily: Requires ironing for a polished look.
– Absorbs moisture: Can feel heavy when sweaty.

Best for: Casual office environments, promotional giveaways, or teams that value comfort and natural fibers.

50/50 Blend (50% Cotton, 50% Polyester): The Balanced Choice

Pros:
– Durability: Polyester adds strength, reducing pilling and wear.
– Wrinkle-resistant: Holds its shape and looks neat longer.
– Minimal shrinkage: More stable after repeated washes.
– Moisture-wicking: Polyester helps move sweat away from the body.
– Cost-effective: Typically more affordable than tri-blends.

Cons:
– Less breathable: Not as airy as 100% cotton.
– Slight synthetic feel: Some users find it less soft than pure cotton.
– Print quality: Can slightly alter print vibrancy, especially with light inks.

Best for: Active work environments, company events, or teams seeking long-lasting, low-maintenance apparel.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon): Softness with Style

Pros:
– Ultra-soft hand feel: Often described as having a “vintage” or “buttery” texture.
– Drapes beautifully: Flattering fit that moves with the body.
– Excellent print surface: Ideal for vintage or distressed designs and soft-hand prints.
– Color retention: Resists fading over time.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Less durable: Rayon can weaken when wet and may wear faster with heavy use.
– Shrinking possibility: Varies by manufacturer; check care instructions.
– Not ideal for heavy-duty use: Better suited for light to moderate wear.

Best for: Creative teams, boutique companies, or branded merch where style and comfort are top priorities.

Final Tips for Choosing the Right Fabric

• Consider your environment: Hot offices? Lean toward cotton or tri-blends. Active roles? Go 50/50 blend.
• Think about branding: Want a premium look? Tri-blend offers a modern, upscale feel.
• Budget matters: 50/50 blends often provide the best value for durability and cost.
• Ask your team: Employee feedback can guide the decision—comfort is key for daily wear.

By matching fabric type to your company’s culture, use case, and budget, you’ll ensure your custom t-shirts are not only great-looking but loved by those who wear them.

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

Ordering custom company t-shirts in bulk can be a cost-effective way to promote your brand, unify your team, or create merchandise. To maximize your savings and ensure high-quality results, consider these essential tips focused on bulk pricing and artwork optimization.

Understand Bulk Quantity Breaks

Screen printing and embroidery companies offer lower per-unit prices as your order quantity increases. These “quantity breaks” typically follow a tiered structure:

• Small orders (12–48 pieces): Higher cost per shirt due to setup fees.
• Mid-size orders (48–144 pieces): Noticeable per-unit savings.
• Large orders (144–288+ pieces): Best pricing; setup costs are spread over more units.

Tip: Always ask for a price sheet showing all available quantity tiers. If you’re close to a break point (e.g., ordering 130 shirts), consider ordering 144 to benefit from the lower rate—even if you don’t need all the shirts immediately.

Choose the Right T-Shirt Style and Brand

Basic, high-volume cotton t-shirts (like Gildan, Hanes, or Bella+Canvas) are the most affordable. Premium or fashion-fit styles cost more. To save:

• Stick with standard colors (e.g., black, white, navy).
• Avoid specialty fabrics (e.g., tri-blend, organic cotton) unless necessary.
• Consider unisex styles to simplify sizing and inventory.

Optimize Your Artwork for Lower Printing Costs

Design complexity directly affects printing cost. Simplify your artwork to reduce production time and expense:

• Limit the number of print colors. Each color requires a separate screen and setup fee. Designs with 1–2 colors are significantly cheaper than multi-color prints.
• Use vector artwork (AI, EPS, PDF). High-resolution raster files (300 DPI PNG, TIFF) are acceptable, but vector files scale perfectly and are preferred by printers.
• Avoid gradients and fine details. These don’t reproduce well with screen printing and may require pricier printing methods (e.g., DTG).
• Keep designs small and centered. Large or full-chest prints use more ink and can increase costs.

Tip: If your logo has many colors, consider creating a simplified, single-color version specifically for apparel.

Request Quotes from Multiple Suppliers

Don’t settle for the first quote. Reach out to at least 3–5 reputable suppliers with your specs (quantity, shirt style, print location, and design). Include:

• Total price (including setup fees, ink, and screens).
• Cost per unit at different quantity tiers.
• Turnaround time.
• Shipping costs.

Compare not just price, but also customer service, quality samples, and minimum order requirements.

Plan Ahead and Avoid Rush Fees

Most printers offer standard turnaround times (7–14 days). Rush orders can increase costs by 25–50%. To avoid these fees:

• Place your order well in advance of your event or launch.
• Confirm production timelines during initial quoting.

Consider Reordering Strategy

If you anticipate future needs, ask about reorder discounts. Some suppliers waive setup fees for repeat orders of the same design within a certain timeframe (e.g., 6–12 months). This makes replenishing stock much more affordable.

Get a Physical Sample Before Bulk Production

Always request a physical sample or digital mockup before committing to a large order. This ensures color accuracy, print quality, and sizing meet your expectations—avoiding costly mistakes.

By leveraging bulk quantity breaks and optimizing your artwork and planning, you can get high-quality custom company t-shirts at the best possible price.