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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Right Fabric for Custom T-Shirts

When ordering custom t-shirts, the fabric you choose significantly impacts comfort, durability, print quality, and overall feel. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps ensure your custom shirts meet your expectations. Here’s a breakdown of each option:

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, soft hand feel and excellent breathability—ideal for warm weather or active wear.
– Comfortable Against Skin: Hypoallergenic and gentle, making it great for sensitive skin.
– Great for Printing: Provides a smooth, consistent surface for screen printing and direct-to-garment (DTG) printing, especially vibrant colors.
– Eco-Friendly Option: Biodegradable and made from renewable resources (especially if organic cotton is used).

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk. Always check garment specs.
– Less Durable: Can wear out faster with frequent washing and may pill over time.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: Holds sweat and takes longer to dry compared to synthetic blends.

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

50/50 Cotton-Polyester Blend

Pros:
– Durability: Polyester adds strength, making the shirt more resistant to wear, shrinking, and pilling.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Affordable: Typically more budget-friendly than 100% cotton or tri-blends.
– Moisture-Wicking: Dries faster than 100% cotton, making it better for light activity.

Cons:
– Less Breathable: Can feel warmer and less comfortable in hot climates.
– Slightly Less Soft: May feel coarser than 100% cotton or tri-blend fabrics.
– Print Quality Variability: Lighter prints may appear slightly faded; not always ideal for ultra-detailed designs.

Best For: Workwear, school spiritwear, budget-conscious bulk orders, and active environments where durability matters.

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

Pros:
– Ultra-Soft Feel: Known for its luxurious, vintage-soft texture—often compared to a well-worn favorite tee.
– Excellent Drape: Flows smoothly over the body, offering a more tailored, modern fit.
– Reduced Shrinkage: Polyester and rayon help minimize shrinking.
– Moisture Management: Balances breathability and quick drying.

Cons:
– Higher Cost: Usually the most expensive of the three options.
– Less Durable: Softer fabric may wear faster with heavy use or frequent washing.
– Special Care Required: Often requires gentle washing and air drying to maintain softness and shape.
– Printing Challenges: The smooth surface may require special inks or pretreatment for vibrant results.

Best For: Premium apparel, fashion-forward brands, boutique orders, and customers seeking a soft, vintage aesthetic.

Final Tips for Choosing

• Consider the Use: Is it for daily wear, events, athletic use, or as a gift? Match fabric to function.
• Think About Climate: Cotton breathes best in heat; blends offer versatility.
• Evaluate Budget: Tri-blends cost more; 50/50 blends offer value and durability.
• Test Samples: Order swatches or sample shirts to feel the fabric and test print quality firsthand.

By understanding the strengths and trade-offs of each fabric, you can confidently choose the perfect material for your custom t-shirt order—balancing comfort, cost, and quality.

How to Get the Best Price on Custom Order T-Shirts (Bulk Quantity & 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 bulk quantity breaks and optimizing your artwork, you can significantly reduce your per-unit cost without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on order size. The more shirts you order, the lower the price per shirt.

• Know the Thresholds: Common quantity breaks are at 25, 50, 75, 100, 250, and 500 units. For example, ordering 99 shirts might cost $10 each, but ordering 100 could drop the price to $6.50 each. Always ask for a full price breakdown.
• Order Slightly Above the Break: If you only need 90 shirts, consider ordering 100 to hit the next pricing tier. The slight overage is often worth the savings.
• Consolidate Orders: Combine multiple smaller needs (e.g., team shirts, event merch, staff uniforms) into one large order to qualify for better pricing.

Choose the Right Garment Wisely

Not all blanks are created equal—and price varies widely.

• Standard vs. Premium Brands: Basic brands like Gildan, Hanes, or Bella+Canvas are more affordable than premium ones like American Apparel or Independent Trading Co. Stick with value-focused brands for bulk orders.
• Color Matters: White and basic colors (black, navy, grey) are typically cheaper than fashion or specialty colors.
• Size Distribution: Order more mid-sizes (M, L) and fewer extremes (XS, 2XL+), as larger quantities of popular sizes reduce waste and can improve pricing.

Optimize Your Artwork for Lower Printing Costs

Printing complexity directly impacts your price. Simplify your design to save money.

• Minimize Print Colors: Each additional color increases setup time and cost. Stick to 1–3 colors whenever possible. A one-color print is significantly cheaper than full-color process.
• Use Simpler Designs: Avoid gradients, tiny text, or intricate details that require expensive printing techniques like simulated process or DTG (direct-to-garment).
• Vector Art is Best: Provide artwork in vector format (AI, EPS, or SVG). It ensures crisp printing and avoids extra fees for file conversion.
• Avoid All-Over Prints: Full-front or full-back prints cost more than standard chest or sleeve prints. Keep designs compact.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote.

• Compare 3–5 Vendors: Reach out to local screen printers and online suppliers (e.g., RushOrderTees, Custom Ink, Printful). Include all specs: shirt type, quantity, print colors, and locations.
• Ask About Hidden Fees: Confirm whether setup fees, art fees, or shipping are included. Some vendors waive setup fees for large orders.
• Negotiate or Bundle: If you plan repeat orders, ask about loyalty discounts or future pricing agreements.

Time Your Order Strategically

• Avoid Rush Fees: Place orders well in advance (4–6 weeks) to skip expedited production or shipping charges.
• Watch for Promotions: Many suppliers offer seasonal deals (back-to-school, holidays) or first-time customer discounts.

Final Tip: Order Extra Shirts

It’s usually cheaper to order 10–15% more than you need during your initial print run than to reorder later. Leftover shirts can be used for replacements, giveaways, or future events—avoiding setup fees on a second order.

By combining smart bulk ordering, simple artwork, and strategic vendor selection, you can get high-quality custom t-shirts at the best possible price. Plan ahead, communicate clearly, and always ask for volume discounts.