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

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

When creating custom embroidered t-shirts, selecting the right fabric is crucial—not only for comfort and durability but also for how well the embroidery will look and hold up over time. The three most popular fabric options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Each has unique characteristics that affect embroidery results. Here’s a detailed comparison to help you choose the best option for your project.

100% Cotton: Classic Comfort with Natural Feel

100% cotton t-shirts are a timeless choice known for their softness, breathability, and natural feel. They’re ideal for everyday wear and offer excellent absorbency.

Pros for Embroidery:
– Provides a stable, firm surface that holds stitches well.
– Offers a clean, classic look—great for traditional or vintage-style designs.
– Holds heat well during the embroidery process, helping stabilize the fabric under the needle.
– Eco-friendly and biodegradable.

Cons for Embroidery:
– Prone to shrinking, especially if not pre-shrunk.
– Can wrinkle easily and may require ironing before or after embroidery.
– Less durable over time; may develop pilling or thinning with frequent washes.

Best For: Casual wear, promotional shirts, corporate branding, and vintage-inspired designs where a natural, soft hand feel is preferred.

50/50 Cotton-Polyester Blend: Balanced Performance

A 50/50 blend combines the best of cotton (softness and breathability) with polyester (durability and shape retention). This balanced fabric is a popular choice for workwear and promotional apparel.

Pros for Embroidery:
– Resists shrinking and wrinkling better than 100% cotton.
– Holds its shape after washing, helping embroidery maintain alignment.
– More durable and long-lasting, especially for frequent wear or work uniforms.
– Often more affordable than 100% cotton or tri-blends.

Cons for Embroidery:
– Slightly less soft than 100% cotton (though modern blends have improved).
– Polyester can sometimes cause “puckering” if not stabilized properly during embroidery.
– May retain heat more than cotton, making it less breathable.

Best For: Work uniforms, team apparel, school shirts, and high-use garments where durability and cost-efficiency are important.

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

Tri-blend fabrics offer a luxurious, ultra-soft hand feel and a slightly heathered appearance. They’re known for their drape and modern aesthetic.

Pros for Embroidery:
– Exceptionally soft and comfortable, with a luxurious drape.
– Resists shrinking and fading better than 100% cotton.
– Offers a modern, fashion-forward look ideal for lifestyle or boutique branding.

Cons for Embroidery:
– More delicate fabric structure—can stretch or shift during embroidery if not stabilized properly.
– Rayon content may be more prone to snagging or fraying.
– Requires careful hooping and backing to prevent distortion.
– May not support heavy or dense embroidery designs well.

Best For: Fashion-forward brands, boutique merchandise, and lightweight, stylish tees where softness and appearance are key. Not ideal for large or intricate embroidery.

Final Tips for Embroidery Success

• Use Proper Stabilization: Especially important with 50/50 and tri-blend fabrics to prevent shifting or puckering.
• Test First: Always embroider a sample on the actual fabric before mass production.
• Consider Design Complexity: Dense designs work better on firmer 100% cotton or 50/50 blends; delicate tri-blends suit simpler, lighter embroidery.
• Think About End Use: Will the shirt be worn daily, for work, or as a fashion statement? Match the fabric to its purpose.

By understanding the strengths and limitations of 100% cotton, 50/50 blends, and tri-blends, you can choose the perfect fabric to make your custom embroidered t-shirts look professional, feel comfortable, and stand the test of time.

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

Purchasing custom embroidered T-shirts in bulk can be a cost-effective way to promote your brand, team, or event. To ensure you get the best price without sacrificing quality, consider the following strategies focusing on bulk pricing and artwork optimization.

Leverage Bulk Quantity Breaks

Most embroidery companies offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost. Here’s how to take full advantage:

• Order in Larger Quantities: Prices typically drop at key thresholds (e.g., 24, 48, 72, 100, 250+ units). Even if you don’t need all shirts immediately, ordering more upfront can save money in the long run.
• Consolidate Designs: Instead of ordering several small batches with different designs, simplify to one or two core designs across multiple shirt colors or styles.
• Plan Ahead: Forecast your needs for the year (e.g., seasonal events, promotions) and place a single large order to maximize savings.
• Ask for Custom Quotes: Many suppliers offer custom pricing for large orders. Reach out directly to negotiate better rates, especially if you’re a repeat customer.

Optimize Your Artwork to Reduce Costs

Embroidery pricing is often based on stitch count—the number of stitches required to complete the design. Lower stitch counts mean lower costs and faster production.

• Simplify Your Design: Avoid overly intricate details, gradients, or tiny text. Stick to bold, clean lines and block letters for better readability and fewer stitches.
• Limit Thread Colors: Each color change increases production time. Aim for 1–3 thread colors maximum to keep costs down.
• Use Vector Art: Provide a high-quality vector file (e.g., .AI, .EPS, .SVG) to ensure clarity and reduce digitizing time. Raster images (like JPEGs) require extra work to convert and may increase charges.
• Follow Size Guidelines: Ensure your design fits standard embroidery areas (e.g., left chest, center back). Oversized designs require more stitches and may incur additional fees.
• Get a Digitizing Quote First: Some companies charge separately for digitizing artwork. Ask if this fee is waived for bulk orders or if they offer free digitizing with large purchases.

Additional Money-Saving Tips

• Choose Affordable Garments: Opt for value-priced but durable blanks (e.g., Gildan, Hanes, or Next Level). Premium brands increase the base cost.
• Stick to Standard Locations: Embroidering on one standard location (like the chest) is cheaper than multi-position stitching (e.g., sleeve + back).
• Compare Multiple Vendors: Get quotes from several reputable embroidery services. Look for those offering free setup, digitizing, or shipping on bulk orders.
• Look for Promotions: Some suppliers offer seasonal discounts or first-time customer deals—take advantage when available.

By combining smart bulk ordering with efficient artwork, you can significantly reduce the cost per unit and get high-quality custom embroidered T-shirts at the best possible price.