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

100% Cotton vs. 50/50 Blend vs. Tri-blend: Your Guide to Choosing the Perfect T-Shirt Fabric

When customizing a t-shirt, the fabric you choose dramatically impacts comfort, durability, and how your design looks. Here’s a breakdown of the three most popular options to help you make the best choice for your needs.

100% Cotton

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warm weather, due to high breathability.
– Natural Feel: Has a classic, familiar cotton texture that many people prefer.
– Great for Printing: Holds ink well, making it ideal for vibrant screen printing and detailed designs.
– Biodegradable: An eco-friendly option at the end of its life cycle.

Cons:
– Prone to Shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable Over Time: May wear out faster with frequent washing and can fade or pill.
– Wrinkles Easily: Requires ironing for a crisp look.

Best For: Casual wear, promotional events, gift shirts, and anyone who prioritizes softness and natural fibers.

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

Pros:
– Durable and Long-Lasting: Polyester adds strength, helping the shirt resist pilling and stretching.
– Resists Shrinking and Wrinkling: Holds its shape better than 100% cotton and requires less ironing.
– Affordable: Often more budget-friendly than tri-blends.
– Good for Active Use: Wicks moisture slightly better than cotton alone.

Cons:
– Less Breathable: Can feel warmer and less comfortable in hot climates.
– Texture: Slightly stiffer feel compared to 100% cotton or tri-blends.
– Printing Limitations: May require different inks for best results, and designs can feel thicker.

Best For: Workwear, team uniforms, school events, or situations where durability and cost are key.

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

Pros:
– Ultra-Soft and Lightweight: Known for a buttery-soft, vintage feel that’s highly comfortable.
– Excellent Drape: Flows nicely on the body, giving a more flattering, relaxed fit.
– Color Retention: Often provides rich, heathered colors with a worn-in look.
– Resists Shrinkage: More stable than 100% cotton due to synthetic content.

Cons:
– More Expensive: Typically the priciest option due to materials and manufacturing.
– Less Durable Over Time: Rayon can weaken when wet and may wear faster with heavy use.
– Not Ideal for Heavy Designs: The soft fabric can pucker under large or thick prints.

Best For: Fashion-forward t-shirts, boutique apparel, gifts, and anyone seeking a premium, soft hand-feel.

Choosing the Right Fabric for You

• Choose 100% Cotton for classic comfort and eco-friendliness.
• Go with 50/50 Blend for durability, affordability, and everyday wear.
• Opt for Tri-blend when you want a luxurious, soft, and stylish look and feel.

Consider your intended use, budget, and desired look—each fabric brings unique benefits to your custom t-shirt.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team—but only if you know how to maximize savings. By leveraging quantity breaks and optimizing your artwork, you can achieve high-quality results at a fraction of the cost. Here’s how.

Understand Bulk Quantity Breaks

Screen printing and embroidery companies use tiered pricing based on order size—known as quantity breaks. The more shirts you order, the lower the per-unit cost.

• Know the Common Tiers: Typical quantity breaks include 12, 24, 50, 72, 100, 250, and 500+ units. For example, the price per shirt might drop significantly at 50 or 100 pieces.
• Order Just Above the Break Point: If 100 shirts cost $5 each but 99 cost $7, it’s often worth ordering one extra to hit the discount tier.
• Plan for Future Needs: If you anticipate needing more shirts later, consider ordering a larger batch now to lock in lower pricing.

Choose the Right Printing Method

The printing technique impacts both cost and quality. Select the method that aligns with your design and budget.

• Screen Printing: Most cost-effective for large orders with simple designs (1–3 colors). Setup costs are high, but per-unit price drops with volume.
• DTG (Direct-to-Garment): Best for complex, full-color designs or small batches. Higher per-shirt cost, but no setup fees—ideal when screen printing isn’t economical.
• Embroidery: Great for logos on polos or hats. Pricing is based on stitch count; simpler designs cost less.

Optimize Your Artwork for Lower Costs

Well-prepared artwork can reduce production time and expenses.

• Simplify Your Design: Fewer colors mean fewer screens and lower printing costs. Convert complex designs to 1–3 spot colors when possible.
• Use Vector Files: Supply artwork in vector format (AI, EPS, or SVG) to avoid re-drawing fees. High-resolution PNGs (300 DPI) are acceptable for DTG.
• Follow Print Area Guidelines: Stay within standard print zones (e.g., left chest, center back). Oversized prints may require additional screens or runs.
• Avoid Gradient and Photo Effects for Screen Printing: These are difficult and costly to reproduce. Use solid colors or opt for DTG instead.

Select Cost-Effective Apparel

The shirt itself is a major cost factor.

• Choose Basic, High-Volume Styles: Brands like Gildan, Hanes, or Bella+Canvas offer affordable blank tees in bulk.
• Stick to One Color: Ordering all shirts in the same color reduces setup and sorting time.
• Compare Fabric Weight and Fit: Heavier fabrics (e.g., 6.1 oz) cost more. Balance quality with budget.

Get Multiple Quotes

Don’t settle for the first vendor.

• Request Quotes from 3–5 Suppliers: Include all details—quantity, shirt type, print location, colors, and artwork.
• Ask About Hidden Fees: Inquire about setup, screen, or digitizing charges. Some companies waive fees for large orders.
• Look for Promotions: Many printers offer seasonal discounts or free setup for first-time bulk orders.

Final Tips for Maximum Savings

• Bundle Orders: Combine multiple events or teams into one large order to increase volume.
• Approve a Physical Sample: Avoid costly reprints by approving a real proof first—some shops offer digital proofs for free.
• Pay in Full Upfront: Some vendors offer a small discount for upfront payment.

By planning smartly around quantity breaks and preparing print-ready artwork, you can significantly reduce the cost per shirt—without sacrificing quality.