Comparison of 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 essential for comfort, durability, appearance, and how your design turns out. The most common fabric choices are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Each has its own advantages and ideal use cases.

100% Cotton

Pros:
– Soft and breathable: Offers a natural feel and excellent comfort, especially in warm weather.
– Eco-friendly: Biodegradable and made from a renewable resource.
– Great for printing: Holds vibrant ink well, especially with screen printing or direct-to-garment (DTG) methods.
– Classic look and feel: Preferred for a traditional, vintage-inspired aesthetic.

Cons:
– Prone to shrinking: May shrink after washing if not pre-shrunk.
– Less durable over time: Can wear out faster, especially with frequent washing.
– Wrinkles easily: Requires ironing for a crisp appearance.
– Absorbs moisture: Can feel heavy when wet and takes longer to dry.

Best For: Casual wear, eco-conscious brands, classic designs, and customers who value natural fibers.

50/50 Cotton-Polyester Blend

Pros:
– Durable and long-lasting: Resists wear, pilling, and fading better than 100% cotton.
– Minimal shrinkage: Holds its shape well after washing.
– Moisture-wicking: Dries faster and resists sweat better than cotton alone.
– Budget-friendly: Often more affordable than premium fabrics.

Cons:
– Less breathable: Can feel warmer and less comfortable in hot climates.
– Less soft initially: May not feel as soft as 100% cotton or tri-blends (though it softens over time).
– Not eco-friendly: Polyester is derived from petroleum and is less biodegradable.

Best For: Workwear, promotional shirts, active environments, and cost-effective bulk orders.

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

Pros:
– Ultra-soft and silky feel: Offers a luxurious, vintage-inspired drape.
– Lightweight and breathable: Comfortable for all-day wear.
– Excellent shape retention: Resists shrinking and wrinkling.
– Faded, vintage look: Ideal for trendy, fashion-forward designs.

Cons:
– Higher cost: More expensive due to the blend complexity.
– Less durable under stress: Can be more prone to snagging or stretching.
– Special care needed: May require gentle washing to maintain quality.

Best For: Fashion apparel, boutique brands, lifestyle brands, and premium custom tees with a soft, lived-in look.

Choosing the Right Fabric for Your Needs

• Choose 100% cotton for a classic, natural feel and eco-friendly appeal.
• Opt for 50/50 blend for durability, affordability, and performance in active or work settings.
• Go with tri-blend for a soft, stylish, and modern look—perfect for fashion-forward custom t-shirts.

Consider your audience, intended use, budget, and desired look when making your fabric choice. The right fabric can elevate your custom t-shirt from ordinary to outstanding.

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

When ordering custom-made t-shirts in bulk, getting the best price involves smart planning, understanding pricing structures, and preparing your artwork correctly. Follow these key strategies to maximize value without sacrificing quality.

Take Advantage of Bulk Quantity Breaks

Screen printers and apparel suppliers offer lower per-unit prices as your order quantity increases. These are known as “quantity breaks.” Here’s how to use them:

• Know the Break Points: Typical breaks occur at 50, 100, 250, and 500 units. For example, pricing might drop significantly when moving from 49 to 50 shirts. Always ask for a pricing tier chart.
• Order Slightly Above Break Points: If you need 45 shirts, consider ordering 50 to benefit from the lower rate.
• Consolidate Orders: Combine needs across teams, events, or departments to reach higher volume tiers.
• Split Sizes, Not Quantities: Most suppliers allow size splits (S, M, L, XL) within a single design order—this doesn’t affect pricing as long as the total quantity meets the break.

Choose the Right T-Shirt Style and Brand

Not all blanks are created equal. To save money:

• Opt for Value-Focused Brands: Gildan, Hanes, and Bella+Canvas offer quality at lower price points.
• Stick to Basic Colors: White and black are typically cheapest; specialty or fashion colors may increase cost.
• Select Lighter Fabric Weights: 4.5 oz or 5.3 oz cotton is often less expensive than premium 6+ oz fabric.

Minimize Print Complexity

Printing cost is heavily influenced by design complexity. Simplify to save:

• Limit Print Colors: Each additional color increases setup and printing time. Stick to 1–3 colors when possible.
• Choose Simpler Designs: Avoid gradients, fine lines, and photorealistic details that require advanced (and costly) printing methods.
• Use One-Location Printing: Printing on just the front (or just the back) reduces labor and setup costs vs. multi-location prints.

Prepare Print-Ready Artwork

A well-prepared design speeds up production and avoids extra fees:

• Use Vector Files (AI, EPS, SVG): These scale without quality loss and are preferred by printers.
• High-Resolution Raster Files (300 DPI): If using Photoshop, ensure your design is 300 dots per inch at actual print size.
• Specify Pantone (PMS) Colors: This ensures color accuracy and reduces guesswork for the printer.
• Provide a Mockup: Help the printer visualize your vision and reduce revision rounds.

Get Multiple Quotes

Don’t settle on the first supplier. Request quotes from at least 3–5 reputable screen printers or online platforms (like Custom Ink, Printful, or local shops). Compare:

• Base shirt cost
• Setup fees
• Printing cost per unit
• Artwork assistance (free or fee-based)
• Turnaround time and shipping

Consider Alternative Printing Methods

Depending on your design and quantity, other methods might offer savings:

• DTG (Direct-to-Garment): Cost-effective for small batches or full-color designs—but higher per-unit cost than screen printing for large runs.
• Dye Sublimation: Great for all-over prints on polyester blends, but limited to light-colored shirts.
• Screen Printing: Best for large orders with simple designs and few colors.

Final Tips for the Best Deal

• Order Off-Season: Avoid peak times (e.g., back-to-school, holidays) when demand—and prices—rise.
• Ask About Discounts: Some suppliers offer first-time, nonprofit, or educational discounts.
• Factor in All Costs: Include shipping, taxes, and any setup fees when comparing quotes.
• Request a Physical Sample: Confirm print and fabric quality before committing to a large order.

By leveraging bulk pricing, simplifying your design, and preparing professional artwork, you can significantly reduce the cost of custom t-shirts—without sacrificing quality.