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

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

When creating custom t-shirts, selecting the right fabric is crucial for comfort, durability, and how your design looks and feels. The most common fabric choices—100% Cotton, 50/50 Blend, and Tri-blends—each offer distinct advantages. Here’s a breakdown to help you choose the best option for your needs.

100% Cotton

Pros:
– Soft and breathable: Naturally comfortable, especially in warm weather.
– Eco-friendly: Biodegradable and often preferred by environmentally conscious buyers.
– Excellent printability: Holds vibrant screen printing and direct-to-garment (DTG) inks well.
– Classic feel: Offers the traditional t-shirt texture many people love.

Cons:
– Prone to shrinking: May shrink after washing, especially if not pre-shrunk.
– Less durable: Can wear out faster and may pill over time.
– Wrinkles easily: Requires more ironing or steaming for a crisp look.

Best For: Everyday wear, casual events, eco-conscious brands, and designs with detailed prints.

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

Pros:
– Durable and long-lasting: Polyester adds strength and resistance to wear and tear.
– Resists shrinking and wrinkling: Holds its shape better through washes.
– Affordable: Typically more budget-friendly than tri-blends or premium cotton.
– Lightweight: Offers a good balance of softness and performance.

Cons:
– Less breathable: May feel warmer than 100% cotton in hot climates.
– Slight sheen: Polyester can give a shinier appearance, which may not suit all designs.
– Pilling over time: Can develop small fabric balls with extended use.

Best For: Workwear, promotional giveaways, school events, and high-use garments where durability matters.

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

Pros:
– Ultra-soft, vintage feel: Known for a smooth, buttery texture and relaxed drape.
– Great drape and fit: Conforms comfortably to the body, ideal for fashion-forward styles.
– Color-retentive: Holds dyes beautifully, resulting in rich, heathered colors.
– Minimal shrinkage: More stable than 100% cotton.

Cons:
– Higher cost: Usually more expensive than cotton or 50/50 blends.
– Less durable for heavy use: Softer fabric may wear faster with frequent washing or rough handling.
– Special care needed: May require gentle washing to maintain softness and shape.

Best For: Fashion tees, boutique apparel, boutique gifts, and premium custom designs where comfort and aesthetics are top priorities.

Choosing the Right Fabric for Your Project

• Choose 100% Cotton if you want natural comfort, breathability, and a classic t-shirt feel.
• Opt for 50/50 Blend when durability, affordability, and shape retention are key—ideal for active use or promotional items.
• Go with Tri-blend for a luxurious, soft hand-feel and modern drape—perfect for trendy, high-end custom shirts.

Understanding these fabric differences ensures your custom t-shirts not only look great but feel great too—matching both your brand’s image and your customers’ expectations.

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

Ordering custom t-shirts in bulk can save you significant money, but getting the best deal requires smart planning—especially when it comes to quantities and artwork. Here’s how to maximize savings while maintaining quality.

Understand Bulk Quantity Breaks

Screen printing and embroidery companies offer lower per-unit prices as your order size increases. These are called quantity breaks.

• Typical Break Points: Common quantity tiers are 12, 24, 50, 100, 250, and 500+ units. Each tier usually drops the per-shirt cost.
• Example: 50 shirts might cost $8 each, while 100 drop to $5 each—a 37.5% savings per shirt.
• Pro Tip: If you need 75 shirts, ordering 100 may still be cheaper overall due to the break. Always compare total cost, not just per-unit price.

Plan ahead to hit the next quantity tier. Even if you don’t need extra shirts now, extras can serve as backups or future inventory.

Choose the Right Shirt Style and Brand

Not all blanks are equal in price.

• Basic Cotton vs. Premium Blends: 100% cotton is usually cheapest. Tri-blend or performance fabrics cost more.
• Brand Matters: Generic or value brands (like Gildan, Hanes, or Bella+Canvas 3001) are more affordable than premium labels.
• Consistency: Stick to one model across your order. Mixing styles increases setup fees and complexity.

Simplify Your Design for Lower Printing Costs

Artwork complexity directly impacts price, especially with screen printing.

• Limit Print Colors: Each color requires a separate screen and setup fee. Stick to 1–3 colors for major savings.
• Smaller Print Area: Larger designs use more ink and may require bigger screens, increasing cost.
• One-Side Printing: Printing on just the front (instead of front and back) cuts setup and labor time.

For complex, full-color designs, consider direct-to-garment (DTG) printing—but only for smaller runs. For bulk, simple screen printing is usually cheapest.

Prepare Print-Ready Artwork

Suppliers often charge for artwork setup or file corrections. Do it right the first time:

• File Format: Provide vector files (.AI, .EPS, or .SVG) for scalability and clean printing. High-resolution PNG or PDF (300 DPI) works if vector isn’t available.
• Color Separation: If using screen printing, separate your design into color layers. A clean, layered file saves the printer time (and your money).
• Size and Placement: Specify exact print size and location (e.g., 10” wide center chest). Avoid guesswork.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote.

• Compare 3–5 Suppliers: Use online tools from reputable printers like Custom Ink, Printful, or local screen shops.
• Ask About Hidden Fees: Confirm if setup, screens, or shipping are included.
• Negotiate: For large orders (250+), ask for a discount. Repeat customers or referrals may get better rates.

Order Samples First

Always order a physical sample (or “mock-up”) before the full run.

• Ensures color accuracy, print quality, and shirt fit.
• Prevents costly mistakes that lead to reprints.

Time Your Order Strategically

• Avoid Rush Fees: Standard turnaround is 7–14 days. Rush jobs can add 25–50% to your cost.
• Off-Peak Discounts: Some printers offer lower rates during slower seasons (e.g., winter for summer tees).

By leveraging bulk quantity breaks, simplifying artwork, and choosing the right materials, you can get high-quality custom t-shirts at the best possible price. Plan ahead, prepare your files, and shop smart—your budget will thank you.