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

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

When designing custom oversized t-shirts, selecting the right fabric is crucial for comfort, durability, and the overall look of your design. The three most popular choices—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits. Here’s a breakdown to help you choose the best option for your needs.

100% Cotton: Classic Comfort and Softness

Pros:
– Super Soft Feel: Especially after the first wash, 100% cotton provides a naturally soft and cozy hand feel.
– Breathable: Excellent moisture absorption and airflow, making it ideal for warm weather or active wear.
– Eco-Friendly Option: Often available in organic forms, appealing to environmentally conscious consumers.
– Great for Printing: Holds vibrant screen prints and DTG (direct-to-garment) designs well.

Cons:
– Prone to Shrinking: Can shrink 5–10% if not pre-shrunk, especially with high-heat drying.
– Less Durable Over Time: May wear out faster with repeated washing and heavy use.
– Wrinkles Easily: Requires more care to maintain a crisp appearance.

Best For: Casual, everyday wear; eco-conscious brands; customers who prioritize softness and natural fibers.

50/50 Blend (50% Cotton, 50% Polyester): The Balanced Performer

Pros:
– Durable and Long-Lasting: Resists shrinking, fading, and pilling better than 100% cotton.
– Low Maintenance: Holds shape well, resists wrinkles, and dries quickly.
– Affordable: Typically priced between cotton and tri-blend options.
– Good Print Surface: Works well with most printing techniques, including screen printing and heat transfer.

Cons:
– Less Breathable: Polyester content reduces breathability compared to pure cotton.
– Slight Sheen: Can have a subtle synthetic look, which may not appeal to all customers.
– Less Soft Initially: May feel slightly stiffer than cotton or tri-blend, though it softens over time.

Best For: Budget-friendly custom tees; promotional wear; high-use environments like events or workplaces.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon): Premium Softness and Drape

Pros:
– Ultra-Soft Hand Feel: Known for a buttery, vintage-like softness right from the start.
– Excellent Drape: Flows smoothly and drapes beautifully—perfect for an oversized, relaxed fit.
– Reduced Shrinkage: Polyester and rayon content minimize shrinking.
– Vintage Aesthetic: Often has a slightly heathered look and a worn-in feel, ideal for fashion-forward designs.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends due to materials and processing.
– Delicate Care: Rayon can weaken when wet, so gentle washing is recommended.
– Print Limitations: May require specific inks or techniques (like water-based) for best results.

Best For: Fashion brands; premium custom apparel; customers seeking a soft, luxurious feel with a modern silhouette.

Final Tips for Choosing Your Fabric

• Consider the Use Case: Is it for daily wear, events, or fashion statements?
• Think About Care: Will customers machine-wash frequently, or is it a specialty item?
• Evaluate Print Needs: Some fabrics work better with certain printing methods.
• Prioritize Comfort vs. Durability: Softness (tri-blend) vs. longevity (50/50 blend) vs. natural feel (cotton).

By matching your fabric choice to your brand’s values, target audience, and intended use, you can create custom oversized t-shirts that look great, feel amazing, and stand the test of time.

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

Custom oversized T-shirts are a popular choice for brands, events, and promotional campaigns due to their trendy fit and high visibility. To get the best price—especially when ordering in bulk—it’s essential to understand how pricing works, leverage quantity breaks, and optimize your artwork. Follow these strategies to save money without sacrificing quality.

Understand Bulk Quantity Breaks

One of the most effective ways to reduce the per-unit cost of custom oversized T-shirts is by ordering in bulk. Most screen printing and embroidery companies offer quantity breaks, where the price per shirt drops as your order size increases.

• Know the thresholds: Common quantity tiers are 25, 50, 100, 250, and 500+ units. For example, the price per shirt might drop significantly when moving from 99 to 100 units.
• Plan ahead: If you’re unsure about demand, consider coordinating with teammates or clients to combine orders and hit the next pricing tier.
• Compare vendors: Different suppliers have different break points. Use online quote tools from multiple print shops to compare pricing at your desired quantity.

Tip: Ordering 250+ units often unlocks the best per-unit pricing and may qualify you for additional discounts or free setup fees.

Choose the Right T-Shirt Brand and Fabric

Not all oversized T-shirts are created equal—and price varies based on brand, material, and quality.

• Opt for mid-tier brands: While premium brands like Bella+Canvas or Independent Trading Co. offer excellent quality, they come at a higher cost. Consider alternatives like Gildan Heavy Cotton or Next Level basics for a balance of comfort and affordability.
• Stick to one color: Ordering all shirts in the same color (e.g., black, white, or heather gray) reduces sorting and handling costs.
• Use cotton blends: 100% cotton is soft but often more expensive. A cotton-polyester blend can be more affordable and durable, especially for activewear or promotional use.

Simplify Your Artwork for Lower Printing Costs

The complexity of your design has a direct impact on pricing—especially with screen printing.

• Limit the number of colors: Each color requires a separate screen and setup fee. Aim for 1–3 colors to minimize costs.
• Use vector artwork: Provide high-resolution vector files (AI, EPS, or SVG) to avoid extra fees for artwork cleanup or redrawing.
• Stick to one print location: Printing on just the front or back is cheaper than multi-location prints (e.g., front + sleeve).
• Avoid gradients and photorealistic designs: These often require simulated process printing, which is more expensive. Opt for flat colors and bold graphics instead.

Tip: Use free tools like Adobe Express or Inkscape to create or simplify your design before sending it to the printer.

Time Your Order Strategically

Printing companies often run seasonal promotions or offer discounts for early orders.

• Avoid peak seasons: Summer and back-to-school periods often come with higher demand and prices. Order during off-peak months (e.g., late fall or winter) for better rates.
• Ask about promotions: Many suppliers offer first-time customer discounts, referral deals, or loyalty programs.
• Get multiple quotes: Use online platforms like Printful, Custom Ink, or local screen printers to compare prices and turnaround times.

Consider Print Method Based on Quantity and Design

Different printing techniques have varying cost structures:

• Screen Printing: Best for large orders (50+ units) with simple designs. Setup costs are higher, but per-unit cost drops significantly with volume.
• DTG (Direct-to-Garment): Ideal for small batches or complex designs, but more expensive per unit. Not cost-effective for bulk orders.
• Heat Transfer or Vinyl: Good for names, numbers, or small logos—but less durable and not ideal for oversized designs.

For bulk custom oversized T-shirts with bold graphics, screen printing is usually the most cost-effective.

Final Tips to Maximize Savings

• Bundle services: Some vendors offer package deals that include design help, free mockups, or discounted shipping for large orders.
• Request a physical proof: Avoid costly reprints by approving a sample first—some shops offer low-cost digital or physical proofs.
• Negotiate: Don’t hesitate to ask for a discount, especially if you’re placing a large order or planning repeat business.

By leveraging bulk quantity breaks, simplifying your artwork, and choosing the right materials and print methods, you can get high-quality custom oversized T-shirts at the best possible price. Plan smart, compare options, and communicate clearly with your supplier to ensure a smooth, budget-friendly process.