Comparison: Screen Printing vs. DTG vs. Heat Transfer for Custom Polo T-Shirts

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

When designing custom polo shirts for your team, brand, or event, selecting the right fabric is crucial. The material affects comfort, durability, appearance, and how well your design prints. Here’s a breakdown of three popular fabric options—100% cotton, 50/50 blend, and tri-blends—to help you make the best choice.

100% Cotton Polos: Soft, Natural, and Classic

Pros:
– Soft and breathable: Offers excellent comfort, especially in warm weather.
– Natural feel: Many people prefer the soft, familiar texture of pure cotton.
– Great for printing: Holds screen printing and embroidery well with vibrant results.
– Biodegradable: An eco-friendlier option compared to synthetic blends.

Cons:
– Prone to shrinking: May shrink if not pre-shrunk or washed improperly.
– Less durable: Can wear out faster with frequent washing and heavy use.
– Wrinkles easily: Requires ironing for a crisp look.
– Absorbs moisture: While breathable, it can become heavy and clingy when wet.

Best For: Casual wear, promotional events, or brands wanting a classic, natural feel.

50/50 Blend Polos: The Balanced Performer

Pros:
– Durable and resilient: Polyester adds strength, reducing pilling and extending shirt life.
– Resists shrinking and wrinkling: Holds its shape better than 100% cotton.
– Affordable: Often more budget-friendly than tri-blends.
– Good printability: Works well with most decoration methods.

Cons:
– Slightly less soft: Can feel a bit rougher than cotton or tri-blends.
– Less breathable: Polyester traps heat and moisture more than cotton.
– Static and odor retention: May hold odors and build static in dry conditions.

Best For: Workwear, team uniforms, or situations where durability and cost matter.

Tri-blend Polos: Soft, Lightweight, and Stylish

Pros:
– Exceptionally soft: A blend of cotton, polyester, and rayon creates a silky, vintage feel.
– Lightweight and drapey: Offers a relaxed, modern fit that moves with you.
– Reduced shrinkage: More stable than 100% cotton.
– Vintage aesthetic: Develops a worn-in look over time, great for lifestyle brands.

Cons:
– Higher cost: Typically more expensive than cotton or 50/50 blends.
– Less durable: The rayon content can weaken fibers over time.
– Delicate printing: Requires specialty inks or methods (like water-based) for best results.
– Not ideal for heavy use: Better suited for fashion than athletic or work environments.

Best For: Fashion-forward brands, boutique promotions, or gifts where comfort and style are key.

Final Tips for Choosing

• Consider the use: Will the polos be worn daily, in active settings, or for special events?
• Think about climate: Cotton and tri-blends breathe better; 50/50 blends offer more resilience.
• Budget matters: 50/50 blends offer a sweet spot between cost and performance.
• Design needs: Detailed prints may work better on cotton or 50/50; tri-blends suit softer, vintage looks.

By matching the fabric to your needs, you’ll ensure your custom polo shirts look great, feel comfortable, and stand the test of time.

How to Get the Best Price for Custom Polo Shirts (Bulk & Artwork Tips)

Ordering custom polo shirts in bulk can be a cost-effective way to promote your brand, team, or event—but getting the best deal requires smart planning. From leveraging quantity breaks to optimizing your artwork, here’s how to maximize savings without sacrificing quality.

Maximize Bulk Quantity Breaks

One of the most effective ways to reduce your per-unit cost is by taking full advantage of bulk pricing tiers. Most suppliers offer significant discounts as your order size increases.

• Know the Quantity Tiers: Suppliers typically offer pricing at intervals like 25, 50, 100, 250, 500, or 1,000+ units. The price per shirt often drops substantially at each tier. For example, you might pay $15 per shirt for 50 units but only $8 per shirt for 500.
• Consolidate Orders: If possible, coordinate with other departments or teams to combine orders. Buying 300 shirts now instead of three separate batches of 100 can save hundreds.
• Forecast Future Needs: If you anticipate needing more shirts in the next 6–12 months, consider ordering a larger batch now to lock in a lower rate. Just ensure the sizes and styles will still be relevant.
• Mix Sizes, Not Styles: Stick to the same brand, style, and color across all shirts. Mixing colors or styles may require separate setups, increasing costs. You can vary sizes (S–XXL) without affecting pricing.

Optimize Artwork for Cost Efficiency

Your design choices directly influence printing costs. Simple, well-prepared artwork can save you money on setup and production.

• Simplify Your Design: Fewer colors and less coverage mean lower printing costs. Screen printing charges are often based on the number of ink colors. A single-color logo is significantly cheaper than a four-color design.
• Use Vector Artwork: Provide your logo in vector format (e.g., .AI, .EPS, or .SVG). Vector files scale without losing quality and reduce setup time, preventing extra charges for redrawing logos.
• Limit Print Locations: Each additional print location (e.g., front, back, sleeve) adds to the cost. Stick to one or two key areas unless branding demands more.
• Choose the Right Decoration Method:
• Screen Printing: Cost-effective for large orders with simple designs.
• Embroidery: Great for a premium look, but more expensive for large designs or high quantities.
• DTG (Direct-to-Garment): Suitable for complex, full-color designs on smaller runs but less economical for bulk.
• Avoid Repeats: Confirm your artwork is approved before production begins. Reprints due to incorrect logos or colors cost extra.

Additional Money-Saving Tips

• Compare Multiple Suppliers: Get quotes from at least 3–5 reputable custom apparel companies. Pay attention to hidden fees like setup, digitizing, or shipping.
• Select Mid-Range Fabric: 100% cotton or performance blends offer a good balance of comfort, durability, and price. Avoid premium fabrics unless necessary.
• Standard Colors: Opt for common polo colors (navy, black, white, heather grey). Specialty or custom-dyed colors often incur upcharges.
• Negotiate and Ask for Discounts: If ordering over 250 units, don’t hesitate to ask for a better rate. Some suppliers offer loyalty programs or seasonal promotions.

By planning your bulk order strategically and preparing print-ready artwork, you can significantly reduce costs while still achieving professional, branded results.