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

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

When designing custom fitted t-shirts, selecting the right fabric is crucial to achieving the desired look, feel, and performance. The three most popular fabric options—100% cotton, 50/50 cotton-polyester blend, and tri-blends—each offer distinct advantages and trade-offs. Here’s a comprehensive comparison to help you choose the best fabric for your custom tees.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, comfortable feel against the skin, ideal for everyday wear.
– Eco-Friendly: Biodegradable and often produced with fewer synthetic chemicals (especially if organic).
– Great for Printing: Absorbs inks well, resulting in vibrant, high-quality prints—especially with screen printing.
– Classic Look: Delivers a traditional, timeless t-shirt feel that many customers prefer.

Cons:
– Prone to Shrinkage: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster and fade more quickly with frequent washing.
– Wrinkles Easily: Requires ironing for a crisp appearance.
– Holds Moisture: Absorbs sweat but dries slowly, which may be less ideal for active use.

Best For: Casual wear, vintage aesthetics, eco-conscious brands, and detailed or bold designs requiring crisp print quality.

50/50 Cotton-Polyester Blend

Pros:
– Durable and Long-Lasting: Polyester adds strength, helping the shirt resist wear, fading, and pilling.
– Resists Shrinkage: More stable through multiple washes than 100% cotton.
– Soft with Structure: Balances comfort with a slightly more structured fit.
– Faster Drying: Wicks moisture better than cotton alone.

Cons:
– Less Breathable: Can feel slightly less airy than 100% cotton, especially in hot weather.
– Potential for Pilling: Lower-quality blends may develop surface fuzz over time.
– Print Quality: While good, prints may not be as vibrant as on 100% cotton due to lower ink absorption.

Best For: Workwear, promotional tees, events, and customers seeking a balance between comfort, durability, and cost-effectiveness.

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

Pros:
– Ultra-Soft and Lightweight: Feels buttery and drapes beautifully—ideal for a fitted, fashion-forward silhouette.
– Excellent Drape: Offers a slightly stretchy, smooth fit that conforms well to the body.
– Moisture-Wicking: Polyester and rayon help manage moisture more effectively than cotton alone.
– Resists Shrinkage and Wrinkling: Holds its shape and appearance after repeated washing.
– Vintage Aesthetic: Often has a slightly heathered look that gives a trendy, worn-in vibe.

Cons:
– Less Durable Under Stress: May be more prone to snagging or stretching out with heavy use.
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Print Limitations: Requires specific printing methods (e.g., water-based inks) for best results; plastisol may crack.

Best For: Fashion-forward brands, boutique apparel, fitted styles, and customers prioritizing softness and modern aesthetics.

Final Tips for Choosing

• Consider the Use Case: Is the shirt for casual wear, athletic use, or promotional branding?
• Think About Your Audience: Do they value sustainability (cotton), durability (50/50), or luxury feel (tri-blend)?
• Factor in Care Instructions: Tri-blends and 50/50s generally require less maintenance.
• Test Samples: Always order swatches or sample shirts to feel the fabric and assess print quality firsthand.

By understanding the strengths and limitations of each fabric, you can confidently select the ideal material that aligns with your brand, design, and customer expectations for custom fitted t-shirts.

How to Get the Best Price for Custom Fitted T-Shirts (Bulk Discounts & Artwork Tips)

Ordering custom fitted t-shirts in bulk can be a cost-effective way to outfit a team, promote your brand, or sell merchandise—but only if you know how to maximize savings. By leveraging bulk quantity breaks and optimizing your artwork, you can significantly reduce your per-unit cost while maintaining high quality.

Maximize Bulk Quantity Breaks

One of the most effective ways to lower your cost per shirt is by ordering in larger quantities. Most screen printers and embroidery companies offer tiered pricing based on volume, so understanding these breaks is essential.

• Know the Standard Tiers: Common quantity breaks include 12, 24, 50, 100, 250, and 500+ units. The larger the order, the lower the unit price. For fitted t-shirts, which often use premium fabrics, ordering 100+ units can cut costs by 30–50% compared to smaller batches.

• Consolidate Sizes: Fitted styles come in narrow size ranges (e.g., S, M, L, XL). To qualify for higher-tier pricing, ensure your total quantity across all sizes meets the break point. For example, 75 smalls and 25 mediums count as 100 total units.

• Combine Orders: If you’re part of an organization or event, pool orders with others to reach higher volume tiers. Many suppliers offer group discounts when orders are placed together.

• Avoid Low Minimums: Some online print-on-demand services have no minimums but charge premium prices. For fitted styles, it’s better to go with a traditional screen printer that rewards bulk orders.

Optimize Artwork for Cost Efficiency

The design you choose can dramatically impact production costs. Simplifying artwork reduces labor and printing time, directly lowering your price.

• Limit Print Colors: Each additional color requires a separate screen and setup fee. Stick to 1–3 colors to minimize costs. For fitted t-shirts, a single-color print on the chest or sleeve is both stylish and budget-friendly.

• Use Vector Art: Provide your logo or design in vector format (AI, EPS, or SVG). High-resolution vector files ensure crisp printing and prevent extra charges for artwork cleanup.

• Simplify the Design: Avoid gradients, fine details, or photorealistic images—they often require costly printing methods like DTG (Direct-to-Garment). Opt for clean, bold lines and solid fills instead.

• Standardize Placement: Printing in the same location (e.g., left chest) across all shirts streamlines the process and reduces setup time. Avoid multiple print locations unless absolutely necessary.

• Proof Before Printing: Always request a digital or physical proof. Fixing artwork errors before production avoids costly reprints.

Additional Money-Saving Tips

• Choose Efficient Printing Methods: For bulk orders with simple designs, traditional screen printing is usually cheaper than DTG. Embroidery is great for logos but more expensive—reserve it for premium giveaways.

• Select Cost-Effective Fitted Styles: Not all fitted t-shirts are created equal. Compare prices across brands like Bella+Canvas, Next Level, or Gildan’s fitted lines. Some offer better pricing at volume.

• Negotiate with Suppliers: Don’t hesitate to ask for a better deal, especially if you’re spending $500+. Mention competitor quotes to encourage price matching.

• Plan Ahead: Rush orders often incur 20–50% surcharges. Place your order well in advance to qualify for standard pricing and free shipping.

By combining smart bulk ordering with efficient artwork practices, you can get high-quality custom fitted t-shirts at a fraction of the expected cost—without sacrificing style or professionalism.