Screen Printing vs. DTG vs. Heat Transfer: Comparison for Photo-Based Custom T-Shirts

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|——–|——————|————————–|—————-|
| Best for Photos | ❌ Poor – Limited color blending; not ideal for gradients or detailed images | ✅ Excellent – High resolution, full-color prints with smooth gradients | ✅ Good – Can reproduce photos well, especially with inkjet or sublimation methods |
| Color Complexity | Limited – Each color requires a separate screen; high setup cost for multi-color designs | Unlimited – Full CMYK printing; handles millions of colors seamlessly | Excellent – Full-color capability; ideal for photographic images |
| Detail & Resolution | Low to Moderate – Fine details and halftones can be lost | High – Crisp detail, excellent for intricate artwork and photos | High – Good detail, but may show slight pixelation under close inspection |
| Setup Time & Cost | High – Requires creating screens; expensive for small runs | Low – Minimal setup; ideal for one-offs and small batches | Very Low – No screen setup; quick and inexpensive for single shirts |
| Durability/Wash Resistance | ✅ Excellent – Thick, durable ink; lasts many washes | ⚠️ Moderate – Can fade or crack over time, especially with frequent washing | ⚠️ Varies – Can peel, crack, or fade; depends on transfer type and quality |
| Fabric Compatibility | Best on 100% cotton; limited on blends and synthetics | Best on 100% cotton (light colors); works on some blends with pretreatment | Works on cotton, polyester, blends; sublimation best on polyester |
| Cost Efficiency | ✅ Best for large orders (50+) – Lower per-unit cost | ❌ Higher per-unit cost; cost-effective for 1–50 shirts | ✅ Low upfront cost; good for 1–20 shirts; per-unit cost stays high |
| Production Speed | Fast for large batches once set up | Slow – Each shirt printed individually; drying/curing adds time | Moderate – Fast printing, but pressing each shirt takes time |
| Softness of Print | Stiff – Thicker ink layer feels heavy on fabric | Soft – Ink absorbs into fabric; feels part of the shirt | Stiff to Medium – Transfer sits on top; can feel plasticky |
| Eco-Friendliness | Moderate – Uses plastisol inks (PVC-based); water-based options available | ✅ Good – Uses water-based inks; lower environmental impact | Varies – Sublimation is eco-friendly; some transfers use plastic coatings |

Summary Recommendation for Photo T-Shirts:
– DTG is the top choice for high-quality photo prints on cotton, especially for small orders.
– Heat Transfer works well for quick, low-volume photo shirts, particularly on blended or dark fabrics.
– Screen Printing is generally not recommended for photo-based designs due to limitations in color and detail.

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

When customizing t-shirts, selecting the right fabric is crucial for comfort, durability, and overall appearance. The most popular fabric choices are 100% cotton, tri-blends, and polyester. Each has unique qualities that suit different needs and preferences. Below is a detailed comparison with visual references to help you make the best choice.

1. 100% Cotton

Overview:
100% cotton t-shirts are made entirely from natural cotton fibers. They are soft, breathable, and ideal for everyday wear. These shirts are especially popular for casual and vintage-style designs.

Pros:
– Soft and comfortable against the skin
– Breathable and great for warm weather
– Absorbs ink well for vibrant screen printing
– Biodegradable and eco-friendly

Cons:
– Prone to shrinking (especially if not pre-shrunk)
– Can wrinkle easily
– Less durable over time compared to blends
– May fade with repeated washing

Best For:
Casual wear, vintage designs, eco-conscious brands, and classic unisex tees.

Photo Example:
(Image: A soft, slightly textured cotton t-shirt with a classic screen-printed logo. The fabric shows a natural matte finish and subtle weave.)

Caption: 100% cotton t-shirt with a soft, breathable feel and natural texture.

2. Tri-Blend (Cotton, Polyester, Rayon)

Overview:
Tri-blend fabrics typically combine 50% polyester, 25% cotton, and 25% rayon. This blend offers a luxurious, heathered look and a buttery-soft feel, making it a favorite for fashion-forward apparel.

Pros:
– Exceptionally soft with a smooth, vintage drape
– Resists shrinking and fading better than pure cotton
– Lightweight and breathable
– Slight stretch for improved fit and comfort

Cons:
– More expensive than cotton or polyester
– Not as breathable as 100% cotton
– May pill over time with friction
– Requires careful washing to maintain softness

Best For:
Fashion tees, women’s cuts, vintage aesthetics, and premium apparel lines.

Photo Example:
(Image: A heather gray tri-blend t-shirt with a slightly shiny, smooth surface. The fabric drapes elegantly on a mannequin.)

Caption: Tri-blend t-shirt with a soft, heathered finish and premium drape.

3. Polyester

Overview:
Polyester t-shirts are made from synthetic fibers. They are highly durable and moisture-wicking, making them ideal for sportswear and performance apparel.

Pros:
– Extremely durable and long-lasting
– Moisture-wicking and quick-drying
– Resists shrinking, stretching, and wrinkles
– Holds bright colors and sublimation prints well

Cons:
– Less breathable; can feel clammy in heat
– Can retain odors if not treated
– Not eco-friendly (derived from petroleum)
– May feel less soft compared to cotton or tri-blend

Best For:
Athletic wear, activewear, outdoor events, and all-over sublimation prints.

Photo Example:
(Image: A sleek, moisture-wicking polyester t-shirt in bright blue with a sublimated graphic. The fabric has a smooth, slightly shiny surface.)

Caption: Polyester performance t-shirt with vibrant sublimation print and smooth texture.

Comparison Summary

| Feature | 100% Cotton | Tri-Blend | Polyester |
|———————–|————————|—————————-|—————————-|
| Softness | Soft | Very Soft (buttery) | Smooth, can feel synthetic |
| Breathability | Excellent | Good | Fair to Poor |
| Durability | Moderate | Good | Excellent |
| Moisture Wicking | Low | Low to Moderate | High |
| Shrink Resistance | Low (unless pre-shrunk)| High | Very High |
| Print Quality | Great for screen print | Good for screen & DTG | Ideal for sublimation |
| Eco-Friendliness | High (natural fiber) | Moderate | Low (synthetic) |
| Best Use | Casual daily wear | Fashion tees, soft styles | Activewear, sportswear |

Final Tips

• For Comfort & Sustainability: Choose 100% cotton.
• For Style & Softness: Go with tri-blend.
• For Performance & Vibrant Prints: Pick polyester.

Consider your audience, use case, and printing method when making your selection. When in doubt, order fabric swatches or sample t-shirts to feel the difference firsthand.

Note: Replace image URLs with actual photos in your final publication for best results.

How to Get the Best Price for Custom Made T-Shirts with Photos

Ordering custom t-shirts with photos can be a cost-effective and impactful way to promote your brand, event, or team. To get the best value—especially when ordering in bulk—it’s important to understand pricing structures, take advantage of discounts, and prepare your artwork properly. Here’s how to maximize savings and quality.

Take Advantage of Bulk Discounts

One of the most effective ways to lower the per-unit cost of custom t-shirts is by ordering in bulk. Most printing companies offer tiered pricing, meaning the more shirts you order, the cheaper each one becomes.

• Order in larger quantities: Typically, prices drop significantly at thresholds like 50, 100, or 250 units. If your budget allows, increasing your order size can cut costs per shirt by 30–50%.
• Compare bulk pricing across vendors: Different companies offer varying bulk discounts. Use online quote tools from multiple suppliers (like Custom Ink, Printful, or RushOrderTees) to compare per-shirt pricing at your desired volume.
• Consider group orders: If you don’t need a large quantity yourself, team up with others—like coworkers, clubs, or event attendees—to pool orders and qualify for bulk rates.

Choose the Right Printing Method

The printing technique impacts both cost and photo quality. For photo-based designs, not all methods are equal.

• DTG (Direct-to-Garment) Printing: Best for full-color photos and detailed artwork. While slightly more expensive than screen printing, DTG has become more affordable, especially for bulk orders.
• Sublimation Printing: Ideal for all-over prints on polyester blends. Great for vibrant, photo-quality results, but limited to light-colored or white garments.
• Avoid screen printing for photos: Screen printing works well for simple logos, but it struggles with gradients and photo realism, often requiring costly color separations.

Optimize Artwork to Reduce Costs

Proper artwork preparation prevents delays, reprints, and added fees.

• Use high-resolution images (300 DPI): Low-res images get pixelated when enlarged. Start with high-quality photos or graphics to avoid extra design fees.
• Design in the correct format: Save artwork as PNG, TIFF, or high-quality PDF. Avoid JPEGs with compression artifacts.
• Follow the printer’s template guidelines: Most companies provide design templates with safe zones and dimensions. Staying within these avoids cropping issues and rework.
• Simplify where possible: Fewer colors and smaller print areas can reduce costs. Consider cropping the photo tightly or using a single focal point instead of full-bleed images.

Choose Cost-Effective Shirt Options

The type of t-shirt you select significantly affects the final price.

• Opt for basic, popular brands: Generic or value-line cotton shirts (like Gildan or Hanes) are cheaper than premium brands (e.g., Bella+Canvas).
• Stick to standard colors: White or lighter-colored shirts are usually cheaper and work best with photo printing. Dark shirts may require an underbase layer, increasing cost.
• Standard cuts and sizes: Unusual cuts or extended sizes can increase prices. Stick to common adult unisex or classic fits unless necessary.

Time Your Order Strategically

• Order off-season: Many suppliers offer promotions in the off-peak months (e.g., winter for summer events).
• Watch for sales and promo codes: Sign up for newsletters from printing companies to receive discounts on first orders or seasonal sales.
• Allow ample production time: Rush shipping adds significant costs. Plan ahead to use standard or economy shipping options.

Request a Physical Sample

Before committing to a large order, order a single sample shirt.

• Verify print quality and fabric feel
• Confirm color accuracy and sizing
• Avoid costly mistakes that could lead to reprints

Many companies offer discounted or free samples, especially for bulk inquiries.

Final Tips

• Negotiate with suppliers: For very large orders (500+ units), don’t hesitate to ask for a custom quote or discount.
• Bundle services: Some vendors offer free design help or waived setup fees for bulk orders—ask about it.
• Use vector files when possible: Though not always needed for photos, vector elements (like text or logos layered over photos) improve scalability and reduce editing costs.

By combining smart ordering strategies with professional artwork preparation, you can achieve high-quality custom photo t-shirts at a fraction of the expected cost.