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

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

When designing custom personalized t-shirts, fabric choice is one of the most important decisions you’ll make. It directly impacts comfort, durability, appearance, and how well your design prints. Here’s a breakdown of the three most popular fabric options—100% cotton, 50/50 blend, and tri-blend—to help you pick the best one for your needs.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear, allowing air circulation to keep you cool.
– Natural feel: Offers a classic, familiar cotton texture that many people prefer.
– Great print surface: Holds screen printing and direct-to-garment (DTG) inks well, resulting in vibrant, crisp designs.
– Eco-friendly option: Biodegradable and often available in organic varieties.

Cons:
– Prone to shrinking: Can shrink significantly (especially if not pre-shrunk) after washing, particularly in hot water.
– Less durable over time: May wear out faster with repeated washes and is more susceptible to pilling.
– Wrinkles easily: Requires ironing for a crisp look.
– Absorbs moisture: While breathable, it retains sweat, which can feel damp during heavy activity.

Best For: Casual wear, vintage-style designs, eco-conscious brands, and customers who prioritize softness and natural fibers.

50/50 Blend: The Best of Both Worlds

Pros:
– Durable and long-lasting: Polyester adds strength, reducing pilling and wear over time.
– Resists shrinking and wrinkling: Holds its shape better through washes and requires less ironing.
– Lightweight and soft: Offers a good balance of comfort and structure.
– Moisture-wicking: Polyester helps draw moisture away from the skin, making it slightly better for active use.
– Affordable: Typically priced between 100% cotton and tri-blend options.

Cons:
– Slightly less breathable: Not as airy as 100% cotton due to synthetic content.
– Can feel less “natural”: Some wearers notice a subtle synthetic feel compared to pure cotton.
– Fuzzing over time: May develop small surface fuzz with heavy use.

Best For: Workwear, promotional shirts, school events, or any use where durability and cost-effectiveness matter. Great for active environments or frequent laundering.

Tri-blend: Premium Softness with a Vintage Look

Pros:
– Luxuriously soft: Combines cotton, polyester, and rayon for a buttery-soft hand feel.
– Vintage aesthetic: Often has a slightly heathered, worn-in look that complements retro or artistic designs.
– Lightweight and drapey: Drapes beautifully on the body, making it ideal for fashion-forward fits.
– Good moisture management: Rayon and polyester help wick moisture and dry quickly.
– Minimal shrinkage: Holds shape well after washing when cared for properly.

Cons:
– Higher cost: More expensive than 100% cotton or 50/50 blends.
– Less durable: Softer fabric may be prone to snagging or thinning with heavy use.
– Special care recommended: Often requires gentle washing and air drying to maintain softness and shape.
– Not ideal for all prints: The heathered texture can slightly affect print opacity and sharpness.

Best For: Fashion tees, boutique brands, artistic designs, and customers looking for a premium, soft, and stylish option.

How to Choose the Right Fabric for Your Custom T-Shirt

• Consider the use: Will it be worn daily, for work, or as a fashion statement?
• Think about your audience: Prioritize comfort (cotton), durability (50/50), or luxury (tri-blend)?
• Match the design style: Bold graphics work well on cotton or 50/50; vintage or artistic prints shine on tri-blends.
• Factor in care and longevity: How often will it be washed? Do you want low maintenance?
• Set your budget: Tri-blends cost more, while 50/50 offers a cost-effective middle ground.

By understanding the strengths and limitations of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the perfect fabric to bring your custom personalized t-shirts to life—balancing comfort, style, and function.

How to Get the Best Price for Custom Personalized T-Shirts

Ordering custom personalized t-shirts in bulk can be a cost-effective way to promote your brand, event, or team spirit. By leveraging quantity breaks and smart design practices, you can significantly reduce costs without sacrificing quality. Here’s how to get the best price on bulk custom t-shirts.

Take Advantage of Bulk Quantity Breaks

Most print shops offer tiered pricing based on the number of shirts ordered. The more you order, the lower the price per unit. To maximize savings:

• Order in larger quantities: Prices often drop at thresholds like 50, 100, 250, or 500 units. Even if you don’t need all shirts immediately, consider ordering ahead to lock in lower rates.
• Combine orders with others: Partner with colleagues, clubs, or organizations to pool orders and reach higher quantity tiers.
• Compare vendors: Different suppliers have different break points. Use online quote tools from multiple vendors (e.g., Printful, Custom Ink, RushOrderTees) to find the best deal for your volume.

Choose Cost-Effective Shirt Styles and Brands

Not all t-shirts are created equal in price. To save money:

• Opt for value-priced blanks: Brands like Gildan, Hanes, or Bella+Canvas offer affordable, good-quality options that are widely used in bulk orders.
• Stick to basic colors: White and standard colors (black, navy, gray) are typically cheaper than specialty or fashion hues.
• Avoid premium fabrics unless necessary: 100% cotton is cost-effective; blended or organic fabrics add to the price.

Simplify Your Artwork to Reduce Printing Costs

Design complexity directly affects pricing—especially with screen printing. Follow these artwork tips to save:

• Limit the number of colors: Each additional ink color increases setup and printing costs. Aim for 1–3 colors in your design.
• Use vector files: Provide artwork in vector format (AI, EPS, or PDF) to avoid extra fees for file conversion.
• Avoid gradients and fine details: These require advanced printing techniques like simulated process or direct-to-garment (DTG), which cost more. Stick to solid fills and bold lines.
• Design for one print location: Printing on just the front (or back) is cheaper than multi-panel designs.

Select the Right Printing Method

The printing technique impacts both cost and quality. For bulk orders, consider:

• Screen printing: Best for large quantities (50+ units), especially with simpler designs. High setup cost but low per-unit price at scale.
• DTG (Direct-to-Garment): Cost-effective for small batches or complex designs, but more expensive per shirt for bulk.
• Heat transfer or vinyl: Suitable for very small orders or specialty items, but not ideal for large volumes due to durability and cost.

Get Quotes and Negotiate

• Request bulk quotes: Provide vendors with your target quantity, shirt type, and design details to get accurate pricing.
• Ask about discounts: Some suppliers offer first-time customer discounts, seasonal promotions, or loyalty rewards.
• Negotiate for large orders: If ordering several hundred shirts, don’t hesitate to ask for a better rate—suppliers often have flexibility.

Order Samples First

Before committing to a large run, order a sample shirt to check print quality, fit, and color accuracy. This avoids costly reprints due to misunderstandings.

Plan Ahead and Avoid Rush Fees

• Allow ample production time: Rush orders can double printing costs. Schedule your order well in advance of your event or deadline.
• Watch for holiday surges: Prices and lead times increase around major holidays and back-to-school seasons.

By combining strategic ordering, smart design choices, and careful vendor selection, you can get high-quality custom t-shirts at the lowest possible price—perfect for branding, events, or group apparel on a budget.