Comparison Table: Screen Printing, DTG, and Heat Transfer for Custom Logo T-Shirts

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

When creating custom logo t-shirts, selecting the right fabric is crucial for comfort, appearance, durability, and print quality. The three most popular choices—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits. Here’s what you need to know to make the best decision for your brand or event.

100% Cotton

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear.
– Eco-friendly appeal: Natural fiber, biodegradable, and often preferred by environmentally conscious consumers.
– Excellent printability: Smooth surface works well with screen printing and direct-to-garment (DTG) methods.
– Classic feel: Offers that traditional, authentic t-shirt experience.

Cons:
– Prone to shrinking: Especially if not pre-shrunk; washing in hot water can cause significant shrinkage.
– Less durable: Tends to wear out faster and may pill over time.
– Wrinkles easily: Requires ironing for a crisp look.
– Holds moisture: Can feel damp when sweating, making it less ideal for active use.

Best For: Casual wear, promotional events, retail apparel, and audiences who value natural fibers and comfort.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Durable and long-lasting: Resists shrinking, fading, and pilling better than 100% cotton.
– Budget-friendly: Often more affordable than tri-blends and high-end cotton.
– Low maintenance: Wrinkle-resistant and dries quickly.
– Good print surface: Works well with most printing techniques, especially screen printing.

Cons:
– Less breathable: Polyester content can trap heat, making it less comfortable in hot climates.
– Slightly less soft: Can feel rougher than 100% cotton or tri-blends, depending on the knit.
– Static and pilling: May develop static electricity and minor pilling with extended wear.

Best For: Corporate giveaways, employee uniforms, school events, and situations where durability and cost-efficiency are priorities.

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

Pros:
– Ultra-soft and smooth: Offers a luxurious, vintage-inspired feel.
– Excellent drape: Flatters the body with a slightly fitted, modern silhouette.
– Color retention: Vibrant prints with a soft, lived-in look that ages gracefully.
– Lightweight and breathable: More comfortable than 50/50 blends in warm weather.

Cons:
– Higher cost: Generally more expensive than cotton or 50/50 options.
– Less durable: May wear out faster with heavy use or frequent washing.
– Shrinking risk: Rayon content can shrink if not washed carefully (cold water recommended).
– Printing limitations: Requires specialized inks or pretreatment for best results with DTG.

Best For: Premium branding, boutique merchandise, fashion-forward designs, and audiences seeking a high-end, soft hand-feel.

Final Tips for Choosing

• Consider the use case: Will the shirt be worn daily, during events, or as a fashion statement?
• Think about your audience: Prioritize comfort, sustainability, or durability based on their preferences.
• Test samples: Order swatches or sample shirts to feel the fabric and test print quality.
• Care instructions matter: Choose a fabric that aligns with how the shirt will be washed and worn.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can choose the perfect fabric to make your custom logo t-shirts look great, wear comfortably, and reflect your brand’s identity.

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

Ordering custom logo t-shirts in bulk can be a cost-effective way to promote your brand, outfit a team, or sell merchandise. To maximize your savings and ensure professional results, focus on smart ordering strategies and artwork preparation.

Leverage Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on order size. Understanding and using these quantity breaks is key to lowering your per-unit cost.

• Know the Common Break Points: Prices typically drop significantly at quantities like 25, 50, 100, 250, and 500 units. For example, ordering 99 shirts might cost much more per shirt than ordering 100.
• Consolidate Orders: If you’re unsure about future needs, consider ordering slightly more than you need now to hit the next pricing tier. The per-unit savings often outweigh storage or minor overage costs.
• Compare Multiple Vendors: Different suppliers have different break points and pricing structures. Get quotes from at least 3–5 reputable printers to find the best deal for your target quantity.
• Consider Color and Style Variety: Mixing shirt colors or styles can still count toward your total quantity for pricing breaks, as long as the design remains the same.

Optimize Your Artwork for Lower Costs

The complexity of your logo directly impacts production costs. Simplified, print-ready artwork saves money and improves print quality.

• Use Vector Files (AI, EPS, PDF): Vector artwork scales perfectly without losing quality. Always provide logos in vector format if possible—this is preferred by professional printers.
• Limit Print Colors: Each additional ink color increases setup time and cost. Stick to 1–3 colors for the most affordable pricing. Consider converting multi-color logos to a single-color version.
• Simplify Complex Designs: Reduce fine details, gradients, and small text. These elements can blur during printing and may require more expensive techniques like digital printing.
• Size Appropriately: Ensure logos are properly sized for the print location (e.g., chest, back). Overly large designs may require larger screens or specialty inks, increasing cost.
• Provide High-Resolution Raster Files if Needed: If a vector isn’t available, submit a high-res PNG or JPEG (at least 300 DPI at print size) to avoid blurry results.

Additional Cost-Saving Tips

• Choose Standard Shirt Styles and Colors: Basic cotton tees in popular colors (like black, white, navy) are usually cheaper than premium or fashion cuts.
• Avoid Flashy Add-Ons: Specialty inks (glow-in-the-dark, metallic), double-sided printing, or embroidery will raise costs. Stick to standard inks unless essential.
• Plan Ahead: Rush orders often come with fees. Place your order well in advance to avoid expedited charges.
• Ask About Discounts: Some printers offer discounts for nonprofits, schools, or repeat customers. Always ask!

By strategically using bulk quantity breaks and preparing clean, print-ready artwork, you’ll reduce production costs and receive high-quality custom t-shirts at the best possible price.