Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

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

Choosing the right fabric for your custom printed t-shirt is crucial—it affects comfort, durability, print quality, and overall appeal. Here’s a breakdown of the three most popular options to help you decide.

100% Cotton: Classic Comfort and Natural Feel

100% cotton t-shirts are a timeless favorite for good reason. Made entirely from natural cotton fibers, these shirts offer exceptional softness and breathability.

Pros:
– Soft, comfortable feel against the skin
– Highly breathable—ideal for warm weather or active wear
– Absorbs ink well, resulting in vibrant, crisp prints
– Biodegradable and eco-friendly (depending on sourcing)
– Great for vintage or authentic look and feel

Cons:
– Prone to shrinking, especially if not pre-shrunk
– Less durable than blended fabrics—may wear out faster with frequent washing
– Can wrinkle easily
– May stretch out over time

Best For: Everyday wear, promotional giveaways, eco-conscious brands, and designs that benefit from a natural, soft hand feel.

50/50 Blend: The Best of Both Worlds

A 50/50 blend combines equal parts cotton and polyester, offering a balanced mix of comfort and performance.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– More durable and longer-lasting
– Lightweight with a slightly smoother texture
– Holds shape well after multiple washes
– Often more affordable than premium cotton or tri-blends

Cons:
– Less breathable than 100% cotton—can feel warmer
– May not feel as soft initially (though modern versions have improved)
– Prints may not appear as vibrant due to polyester’s lower ink absorption

Best For: Workwear, school events, sports teams, or budget-conscious bulk orders where durability matters.

Tri-Blends: Softness, Drape, and Modern Style

Tri-blend fabrics typically combine cotton, polyester, and rayon (often in a 50/25/25 ratio). This blend is known for its luxurious feel and vintage aesthetic.

Pros:
– Exceptionally soft with a silky, lightweight texture
– Superior drape—hugs the body without clinging
– Slight natural stretch for added comfort
– Resists shrinking and holds shape well
– Offers a heathered, vintage look that’s popular in fashion

Cons:
– Higher price point due to premium materials
– Rayon can be less durable and prone to pilling over time
– May require more delicate washing care
– Ink absorption varies—some printers adjust techniques for best results

Best For: Fashion-forward apparel, boutique brands, retail sales, and designs aiming for a soft, vintage-inspired look.

How to Choose the Right Fabric for Your Needs

Consider these factors when making your decision:
– Purpose: Is it for promotional use, retail, or personal wear?
– Comfort vs. Durability: Prioritize softness (cotton or tri-blend) or longevity (50/50 or tri-blend)?
– Climate: Choose breathable cotton for hot areas, blends for all-season wear.
– Design: Detailed, vibrant artwork often works best on cotton or tri-blends.
– Budget: 50/50 blends offer great value; tri-blends are premium.

Ultimately, the best fabric depends on your audience, brand image, and intended use. Test samples when possible to feel the difference firsthand before placing a large order.

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

Ordering custom printed t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To ensure you get the best possible price without sacrificing quality, it’s important to understand how bulk pricing works and how to prepare your artwork correctly. Here’s a comprehensive guide to help you save money and get excellent results.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order volume—known as “quantity breaks.” These pricing tiers reward larger orders with lower per-unit costs.

• Typical Quantity Breaks: Common thresholds include 25, 50, 100, 250, and 500+ units. For example, ordering 49 shirts might cost $10 each, while ordering 50 could drop the price to $7.50 each.
• Maximize Savings: Always order at the start of a new tier. If you need 45 shirts, consider bumping up to 50 to take advantage of the lower price per unit.
• Forecast Demand: Accurately estimate how many shirts you’ll need. Over-ordering unnecessarily can waste money, but under-ordering may mean missing out on better pricing later.

Choose the Right Printing Method

The printing technique significantly impacts cost, especially for bulk orders.

• Screen Printing: Best for large orders (50+ units) with simple, bold designs. Cost per shirt decreases with volume because setup (screen creation) is a one-time fee. Ideal for cotton or cotton-blend garments.
• Direct-to-Garment (DTG): Suitable for smaller runs (under 50) or full-color, photo-realistic designs. More expensive per shirt at scale, but no setup fees for simple artwork.
• Heat Transfer or Dye Sublimation: Good for all-over prints or performance wear. Often more expensive, so use only when design demands it.

Simplify Your Design

Complex artwork increases production time and costs. Streamline your design to save money.

• Limit Colors: Each color in screen printing requires a separate screen and setup. Stick to 1–3 colors to reduce costs.
• Avoid Gradients and Fine Details: These are hard to reproduce and may require more expensive printing methods. Use flat colors and bold lines instead.
• Use Vector Art: Provide artwork in vector formats (AI, EPS, SVG) for crisp, scalable printing. Avoid low-resolution JPEGs.

Provide Print-Ready Artwork

Properly formatted artwork prevents delays and extra fees.

• High Resolution: For raster images, use 300 DPI at actual print size.
• Correct Color Mode: Use CMYK for accurate color matching in print (not RGB).
• Clear Bleed and Safe Zones: Include a 0.25-inch bleed and keep critical elements within the safe zone to avoid trimming issues.
• File Types: Supply vector files (AI, EPS, PDF) when possible. If using raster, provide PNG or high-res TIFF.

Compare Multiple Vendors

Don’t settle for the first quote. Shop around and ask the right questions.

• Request Detailed Quotes: Ensure pricing includes setup fees, ink colors, garment cost, and shipping.
• Ask About Hidden Fees: Some vendors charge extra for screens, color changes, or rush orders.
• Read Reviews: Check customer feedback on quality, turnaround time, and customer service.

Choose the Right Garment

T-shirt cost varies widely based on brand, material, and quality.

• Standard Cotton: Most affordable. Brands like Gildan or Hanes offer budget-friendly bulk options.
• Premium Blends: Slightly more expensive but offer better comfort and durability (e.g., Bella+Canvas, Next Level).
• Buy in Bulk: Some suppliers offer additional discounts if you order the same style and color across all shirts.

Plan Ahead and Avoid Rush Fees

Rush orders often come with 25–50% surcharges.

• Order Early: Allow 2–3 weeks for production and shipping.
• Schedule in Advance: For events or campaigns, finalize designs and quantities well ahead of time.

Bundle Orders When Possible

Combine multiple orders (e.g., staff, customers, events) into one large batch to reach higher quantity breaks and reduce setup costs.

By leveraging bulk quantity breaks, optimizing your artwork, and choosing the right printing method and vendor, you can significantly reduce the cost per shirt while maintaining high quality. With a little planning and attention to detail, your custom t-shirt project can be both affordable and impactful.