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

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

When designing custom t-shirts, selecting the right fabric is crucial for comfort, durability, appearance, and print quality. The three most popular choices—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits and trade-offs. Understanding these differences will help you make the best choice for your project.

100% Cotton: Classic Comfort and Breathability

100% cotton t-shirts are a timeless favorite for their soft feel and natural fibers. They are typically made from combed or ring-spun cotton, which enhances softness and reduces pilling.

Pros:
– Soft and breathable: Ideal for warm weather and all-day wear.
– Great for printing: Absorbs ink well, producing vibrant, crisp designs.
– Natural and biodegradable: An eco-friendly option preferred by many consumers.
– Absorbs moisture: Wicks sweat effectively, keeping you comfortable.

Cons:
– Prone to shrinking: May shrink up to 5–7% after washing, especially if not pre-shrunk.
– Less durable over time: Can wear out faster with repeated washing and use.
– Wrinkles easily: Requires ironing for a crisp look.

Best For: Everyday wear, eco-conscious brands, screen printing (especially vintage or bold graphics), and customers who prioritize softness and natural fibers.

50/50 Blend: The Balanced Choice

A 50/50 blend combines 50% cotton and 50% polyester, offering a middle ground between comfort and performance.

Pros:
– Resists shrinking and wrinkling: Holds its shape better than 100% cotton.
– Durable and long-lasting: Polyester adds strength and extends the shirt’s lifespan.
– Budget-friendly: Often less expensive than premium cotton or tri-blends.
– Good for printing: Works well with most printing techniques, including DTG and screen printing.

Cons:
– Less breathable: Polyester reduces airflow, making it warmer to wear.
– Can feel less soft: May have a slightly synthetic feel, especially in lower-quality blends.
– Pilling over time: May develop small fabric balls with repeated use.

Best For: Promotional events, team uniforms, workwear, and high-volume orders where durability and cost are key factors.

Tri-Blend: Softness Meets Performance

Tri-blend fabrics typically combine 50% polyester, 25% combed cotton, and 25% rayon (often modal or viscose). This mix creates a luxuriously soft, slightly heathered fabric with a vintage drape.

Pros:
– Ultra-soft and lightweight: Feels buttery and drapes beautifully.
– Great drape and fit: Conforms to the body for a relaxed, modern look.
– Resists shrinking and fading: Polyester content enhances durability.
– Unique aesthetic: The heathered look gives a stylish, lived-in vibe.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Less absorbent: Rayon and polyester don’t wick moisture as well as cotton.
– Can be delicate: May require gentler washing to maintain softness and prevent pilling.

Best For: Fashion-forward designs, boutique brands, premium apparel, and soft-hand feel prints like water-based inks or vintage-style graphics.

Final Tips for Choosing Your Fabric

• Consider the end use: Will the shirt be worn daily, for sports, or as a fashion statement?
• Think about print type: Some fabrics work better with certain printing methods (e.g., tri-blends for soft prints, cotton for bold screen prints).
• Know your audience: Prioritize comfort, sustainability, or durability based on customer preferences.
• Order samples: Always test fabric swatches or sample shirts to feel the texture and assess print quality.

By weighing these factors, you can confidently select the ideal fabric—whether you’re going for classic cotton comfort, the balance of a 50/50 blend, or the luxurious softness of a tri-blend.

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

Ordering custom-designed t-shirts in bulk can be a cost-effective way to promote your brand, event, or team—but getting the best price requires smart planning. Here’s how to save money while maintaining quality, using bulk quantity breaks and optimizing your artwork.

Leverage Bulk Quantity Breaks

Most screen printing and print-on-demand companies offer tiered pricing based on order size. The more shirts you order, the lower the per-unit cost.

• Order in larger quantities: Common quantity breaks are 25, 50, 100, 250, and 500+ units. Jumping to the next tier (e.g., from 75 to 100) often gives a significant price reduction per shirt.
• Consolidate orders: If multiple departments or teams need shirts, combine your orders into one large batch.
• Stock up for future use: If designs are timeless (e.g., company logos), order more than you need now to lock in lower rates.
• Avoid mixed sizes and colors: Each color or size variation may count as a separate “setup,” increasing costs. Stick to one design, color, and consistent sizing breakdown (e.g., S/M/L/XL) to maximize savings.

Optimize Your Artwork to Reduce Printing Costs

Artwork complexity directly impacts printing costs. Simpler designs mean fewer screens, less ink, and faster production.

• Limit the number of colors: Each ink color requires a separate screen and setup fee. Stick to 1–3 colors for the best pricing.
• Use vector files (AI, EPS, SVG): High-resolution vector artwork ensures crisp printing and avoids extra fees for file correction.
• Avoid gradients and fine details: These can be difficult and expensive to reproduce via screen printing. Opt for bold, flat colors and clean lines.
• Design with placement in mind: Printing on one location (e.g., center chest) is cheaper than multi-location prints (front and back).
• Confirm print size and positioning: Provide exact measurements to prevent rework and ensure consistency across orders.

Compare Vendors and Negotiate

Don’t settle for the first quote. Get estimates from multiple suppliers—local printers, online services (like Printful, Custom Ink, or RushOrderTees), and regional screen printers.

• Ask about setup fees and minimums: Some vendors waive or discount setup fees for bulk orders.
• Inquire about package deals: Bundled services (design assistance, free mockups, shipping discounts) can add value.
• Build long-term relationships: If you plan repeat orders, ask about loyalty discounts or future pricing guarantees.

Choose the Right Shirt Style and Material

Basic cotton shirts are cheaper than premium or performance fabrics. Balancing cost and quality is key.

• Stick to standard brands: Gildan, Hanes, and Bella+Canvas offer affordable, reliable options with bulk pricing.
• Avoid specialty inks: Metallic, glitter, or discharge inks increase costs. Use them sparingly, if at all.
• Request fabric swatches: Ensure the shirt quality meets your expectations before placing a large order.

Final Tips

• Order a sample first: Pay for a single prototype to check print quality, sizing, and design accuracy before going bulk.
• Plan ahead: Rush fees can double costs. Place orders 2–4 weeks in advance.
• Use promo codes and seasonal deals: Many online printers offer discounts for first-time buyers or holiday sales.

By leveraging bulk pricing, simplifying your design, and choosing the right vendor, you can get high-quality custom t-shirts at the best possible price.