Comparison of Custom T-Shirt Printing Methods

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

When creating custom embroidered t-shirts, selecting the right fabric is crucial for both the appearance of your design and the comfort of the wearer. The three most common fabric options—100% cotton, 50/50 cotton-polyester blends, and tri-blends—each offer distinct advantages and drawbacks for embroidery. Here’s a detailed comparison to help you make an informed choice.

100% Cotton

Pros:
– Classic Feel & Look: Offers a soft, natural hand feel and a traditional t-shirt appearance that many people prefer.
– Excellent Stitch Definition: Holds embroidery well, providing crisp, clear detail—ideal for intricate logos or text.
– Highly Breathable: Allows for good air circulation, making it comfortable in warm weather.
– Eco-Friendly Appeal: Biodegradable and often favored by consumers seeking sustainable options.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk; can shrink up to 5–7% after washing, potentially distorting the embroidery.
– Less Durable Over Time: More susceptible to pilling, fading, and wear with repeated washing.
– Can Wrinkle Easily: May require ironing to maintain a polished look.
– Absorbs Moisture: Can feel damp when sweating, making it less ideal for active wear.

Best For: Casual wear, vintage-style designs, corporate shirts, or when a premium natural fabric is desired.

50/50 Cotton-Polyester Blend

Pros:
– Reduced Shrinkage: Polyester fibers help stabilize the fabric, minimizing shrinkage during washing (typically 2–3%).
– Increased Durability: More resistant to pilling, fading, and general wear than 100% cotton.
– Cost-Effective: Often priced between 100% cotton and tri-blends, offering a balance of performance and affordability.
– Holds Shape Well: Maintains fit and structure over time, which helps keep embroidery aligned.

Cons:
– Slightly Stiffer Feel: The polyester content can make the fabric less soft than 100% cotton, especially when new.
– Less Breathable: Polyester traps heat and moisture more than cotton, which can reduce comfort in hot conditions.
– Potential for Sheen: May reflect light differently than cotton, affecting how embroidery thread colors appear.

Best For: Workwear, promotional shirts, school apparel, or any high-use garments where durability and cost are priorities.

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

Pros:
– Ultra-Soft Hand Feel: Blended with rayon for a smooth, luxurious, and lightweight texture—often described as “buttery soft.”
– Excellent Drape: Flows nicely on the body, giving a more tailored, modern look.
– Minimal Shrinkage: Highly stable fabric that retains shape and size after repeated washings.
– Resistant to Wrinkling: Maintains a neat appearance with little to no ironing required.

Cons:
– Challenging for Embroidery: The softness and drape can make the fabric prone to puckering during stitching. Requires skilled digitizing and stabilizing.
– Less Structural Support: Can stretch or distort under heavy or dense embroidery designs.
– Higher Cost: Generally more expensive than 100% cotton or 50/50 blends.
– Durability Concerns: While soft, the rayon content is less durable and may wear or pill faster under friction.

Best For: Fashion-forward tees, boutique apparel, or lightweight garments where comfort and drape are top priorities—best with small, simple embroidery.

Key Considerations When Choosing

• Design Complexity: Intricate or dense designs work best on sturdier fabrics like 100% cotton or 50/50 blends. Avoid heavy embroidery on tri-blends.
• End Use: Consider whether the shirt will be worn casually, for work, or during physical activity.
• Wash Frequency: High-wear garments benefit from the durability of polyester blends.
• Budget: 50/50 blends often offer the best value, while tri-blends are premium-priced.
• Stabilization: All fabrics benefit from proper backing, but tri-blends especially require medium to heavyweight stabilizers to prevent distortion.

Final Recommendation

For crisp, durable embroidery, 100% cotton or 50/50 blends are your safest choices—opt for cotton if softness and natural appeal are key, and 50/50 if you need durability and shrink resistance. Choose tri-blends only when the priority is comfort and fashion, and the embroidery is minimal and well-supported with proper techniques.

By matching your fabric choice to your design and use case, you’ll ensure your custom embroidered t-shirts look great and stand the test of time.

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

Getting custom embroidered T-shirts in bulk can be a cost-effective way to promote your brand, team, or event. By leveraging quantity breaks and optimizing your artwork, you can significantly reduce costs without sacrificing quality. Here’s how to get the best price on bulk custom embroidery.

Take Advantage of Bulk Quantity Breaks

One of the easiest ways to lower your per-unit cost is by ordering in larger quantities. Most embroidery suppliers offer tiered pricing, where the price per shirt decreases as your order size increases.

• Know the Volume Thresholds: Common quantity breaks include 24, 48, 72, 100, 250, and 500+ units. Ordering just above a threshold (e.g., 101 instead of 99) can save you money.
• Consolidate Orders: If possible, coordinate with other departments, teams, or events to combine orders and hit higher volume tiers.
• Future-Proof Your Order: If you anticipate needing shirts later, order extra now to benefit from lower rates—just ensure styles and sizes will still be relevant.

Simplify Your Embroidery Design

The complexity of your design directly affects pricing. Embroidery is priced by stitch count, so fewer stitches mean lower costs.

• Limit Stitch Count: Aim for designs under 5,000–7,000 stitches. Simplify logos by reducing detail, avoiding gradients, and using solid colors.
• Use Fewer Thread Colors: Each color change requires a manual thread swap. Limit your palette to 3–5 colors to reduce labor time and cost.
• Avoid Small Text and Fine Details: Tiny lettering or intricate lines may require more precision and higher stitch density, increasing time and cost.

Choose the Right Garments

The type of T-shirt you select impacts both quality and price.

• Standard vs. Premium Apparel: Basic cotton tees are less expensive than performance or blended fabrics. Stick to standard options unless specific features are required.
• Buy in Bulk from the Same Brand: Ordering the same style across sizes improves pricing and streamlines production.
• Consider Unisex Styles: These often come in larger volume options and are typically more affordable than gender-specific cuts.

Optimize Artwork for Embroidery

Proper artwork preparation saves time and money during digitizing (the process of converting your logo into an embroidery file).

• Submit High-Resolution Vector Files: Use .AI, .EPS, or .PDF vector formats for clean scaling. Avoid low-res .JPG or .PNG files.
• Outline Fonts and Convert Text to Paths: This ensures your text appears correctly across devices and prevents font compatibility issues.
• Specify Colors with PMS or Thread Charts: Use standard embroidery thread systems (like Pantone or Madeira) to avoid guesswork and revisions.
• Get a Free Digitizing Quote: Many suppliers offer free or discounted digitizing for large orders—ask upfront.

Compare Multiple Suppliers

Don’t settle for the first quote. Shopping around helps you find the best value.

• Request Detailed Quotes: Ensure pricing includes digitizing, setup, thread changes, and any hidden fees.
• Look for Package Deals: Some companies offer free digitizing or setup fees with large orders.
• Check Reviews and Samples: Prioritize quality and reliability—cheap prices aren’t worth it if the stitching is poor.

Time Your Order Strategically

Production timelines and seasonal demand can influence pricing.

• Order Early: Avoid rush fees by placing orders well in advance of your event or deadline.
• Avoid Peak Seasons: Holidays and back-to-school periods may increase demand and prices. Plan ahead to secure better rates.

By combining bulk ordering, smart design choices, and strategic supplier selection, you can get high-quality custom embroidered T-shirts at the best possible price.