Comparison: Screen Printing, DTG, and Heat Transfer for Custom Fire Dept T-Shirts

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

When ordering custom t-shirts for your fire department, selecting the right fabric is crucial for comfort, durability, and appearance—especially under demanding conditions. Here’s a breakdown of the three most common fabric options to help you make an informed decision.

100% Cotton

Pros:
– Soft and breathable: Offers excellent comfort, especially in hot environments, allowing air to circulate.
– Natural feel: Many people prefer the soft, familiar hand feel of pure cotton.
– Great for printing: Holds vibrant ink well, making it ideal for detailed department logos and designs.
– Biodegradable: An eco-friendly option at end of life.

Cons:
– Prone to shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less durable: Tends to wear out faster with frequent washing and heavy use.
– Wrinkles easily: Requires ironing for a crisp look.
– Holds moisture: Absorbs sweat but dries slowly, which may be uncomfortable during physical activity.

Best For: Casual wear, events, or departments prioritizing softness and print quality over heavy-duty use.

50/50 Cotton-Polyester Blend

Pros:
– Durable and resilient: Withstands repeated washing and daily wear better than 100% cotton.
– Resists shrinking and wrinkling: Holds its shape and appearance over time.
– Faster drying: Polyester helps wick moisture and dry quicker than pure cotton.
– Affordable: Typically more cost-effective than tri-blends while offering improved performance.

Cons:
– Less breathable: Not as airy as 100% cotton, which may lead to overheating during intense activity.
– Slighter stiffer feel: The texture can feel less soft initially compared to cotton or tri-blends.
– Pilling over time: May develop small fabric balls with prolonged use.

Best For: Departments needing durable, low-maintenance shirts for daily duty, training, or public outreach.

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

Pros:
– Luxuriously soft: Offers a smooth, lightweight, and silky feel—often compared to vintage or premium tees.
– Excellent drape: Drapes well on the body for a flattering, modern fit.
– Moisture-wicking: Polyester helps move sweat away, while rayon adds softness and breathability.
– Resists shrinking and fading: Maintains shape and color longer than 100% cotton.

Cons:
– Higher cost: More expensive than both 100% cotton and 50/50 blends.
– Less durable under stress: May not withstand heavy abrasion or rough handling as well as other blends.
– Requires gentle care: Best washed in cold water and air-dried to preserve fabric integrity.

Best For: Commemorative shirts, off-duty apparel, or departments wanting a premium, soft feel for events and casual wear.

Final Tips for Fire Departments

• Consider the use case: Daily duty shirts benefit from durability (50/50 blend), while event shirts can prioritize comfort (tri-blend).
• Prioritize fit and sizing: Ensure consistent sizing across fabric types, as blends can fit differently.
• Test before bulk ordering: Order samples to evaluate comfort, print quality, and durability.
• Check care instructions: Educate members on proper washing to extend shirt life, especially with tri-blends.

Choosing the right fabric ensures your custom fire department t-shirts look great, perform well, and stand the test of time—whether on the job or in the community.

How to Get the Best Price for Custom Fire Department T-Shirts (Bulk Quantity Breaks, Artwork Tips)

Ordering custom T-shirts for your fire department can be a cost-effective way to build team spirit, promote your unit at public events, or commemorate milestones. To get the best price—especially when ordering in bulk—it’s important to understand quantity breaks, pricing strategies, and artwork best practices. Here’s how to save money without sacrificing quality.

Take Advantage of Bulk Quantity Breaks

Most screen printing and apparel companies offer tiered pricing based on order volume. The more shirts you order, the lower the price per unit. Typical bulk quantity breaks include:

• 12–24 pieces
• 25–49 pieces
• 50–74 pieces
• 75–99 pieces
• 100+ pieces

Tip: Aim for the next pricing tier. For example, if you need 45 shirts, consider ordering 50 to drop into a lower per-unit price bracket. The small increase in quantity often results in significant savings overall.

Pro Tip: Combine orders across shifts, divisions, or even neighboring fire departments to meet higher volume tiers and share the savings.

Choose the Right Shirt Style and Brand

Not all T-shirts are created equal—and price varies widely by brand, fabric, and fit. To keep costs down:

• Opt for value-priced blanks like Gildan, Hanes, or Bella+Canvas 3001. These are durable, comfortable, and widely available.
• Stick to standard colors (e.g., white, black, navy). Specialty or fashion colors may increase cost.
• Avoid ultra-premium brands unless necessary—stick to mid-tier options for the best balance of price and quality.

Minimize Print Costs with Smart Design Choices

Printing is where costs can quickly add up. Here’s how to keep it affordable:

Limit the Number of Print Colors

Each additional color in your design requires a new screen and setup fee. To save:

• Use one- or two-color designs (e.g., white and red).
• Convert complex logos to single-color versions or silhouettes.

Reduce Print Locations

More print locations = higher cost. Consider printing:

• Front only (most cost-effective)
• Front and back (adds ~$1–$2 per shirt)
• Avoid sleeves, collars, or side prints unless essential

Prepare Artwork to Avoid Setup Fees

Many printers charge artwork setup fees if your design isn’t print-ready. Avoid these extra costs with proper preparation:

• Submit vector files (AI, EPS, or PDF with editable vectors) for crisp, scalable logos.
• If using raster images (JPG, PNG), ensure they are 300 DPI at actual print size.
• Outline all text in design software to prevent font issues.
• Provide Pantone (PMS) color codes for accurate color matching.

Bonus: Offer a simple, clean design that uses minimal ink—this reduces print time and material use, lowering your overall cost.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote. Contact at least 3–5 reputable screen printers (local and online) and provide identical specs to compare apples to apples.

Ask about:
– Volume discounts beyond standard tiers
– Non-profit or government pricing (some printers offer discounts for fire departments)
– Free or discounted setup for repeat orders

Plan Ahead to Avoid Rush Fees

Rush orders can increase costs by 25–50%. To avoid this:

• Place your order 4–6 weeks in advance of your event or delivery date.
• Confirm production and shipping timelines early.

Consider Hybrid Printing for Large Runs

For orders over 100–150 shirts, direct-to-garment (DTG) or plastisol transfer may not be cost-effective. Stick with traditional screen printing for the lowest per-unit cost on bulk orders.

By leveraging bulk quantity breaks, optimizing your design, and choosing the right supplier, your fire department can get high-quality custom T-shirts at the best possible price. Plan smart, print simple, and save big.