Comparison of Custom T-Shirt Printing Methods

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

When ordering custom printed t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and print quality. Understanding the main fabric options—100% cotton, 50/50 blends, and tri-blends—can help you make the best choice for your needs.

100% Cotton

Pros:
– Soft and Breathable: Pure cotton is naturally soft, especially after washing, and highly breathable, making it ideal for warm weather and everyday wear.
– Eco-Friendly: Cotton is biodegradable and often preferred by those seeking sustainable apparel options.
– Great for Printing: Absorbs ink well, allowing for vibrant and crisp print results, especially with water-based and plastisol inks.
– Comfortable Against Skin: Hypoallergenic and gentle, suitable for sensitive skin.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk; washing in hot water can cause significant shrinkage.
– Less Durable: Tends to wear out faster and may pill or fade over time with frequent washing.
– Wrinkles Easily: Requires ironing or steaming to maintain a neat appearance.
– Holds Moisture: Absorbs sweat but dries slowly, which can feel damp during intense activity.

Best For: Casual wear, promotional giveaways, eco-conscious brands, and soft-hand feel prints.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Durable and Resilient: The polyester adds strength, reducing wear and tear and helping the shirt maintain its shape.
– Resists Shrinking and Wrinkling: More stable in the wash and dryer than 100% cotton.
– Affordable: Often less expensive than tri-blends while offering improved performance over cotton alone.
– Good Print Surface: Provides a solid base for screen printing and heat transfers; holds color well.

Cons:
– Less Breathable: Polyester can trap heat, making the shirt feel warmer and less comfortable in hot conditions.
– Slightly Less Soft: Can feel stiffer than 100% cotton, especially when new.
– Pilling Potential: May develop small fabric balls over time with friction.

Best For: Workwear, events with high activity, budget-friendly bulk orders, and environments where durability matters.

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

Pros:
– Ultra-Soft and Lightweight: Known for a luxurious, vintage-like feel that’s soft from the first wear.
– Excellent Drape: Flows well and conforms comfortably to the body, giving a more modern, fitted look.
– Breathable and Moisture-Wicking: Rayon enhances softness and breathability, while polyester helps wick moisture.
– Reduced Shrinkage: More stable than 100% cotton, though care instructions should still be followed.
– Great for Vintage Prints: Ideal for achieving a retro or distressed aesthetic with printing.

Cons:
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Less Durable: The inclusion of rayon can make the fabric more delicate and prone to snagging.
– Care Sensitivity: Often requires gentle washing and air drying to preserve softness and shape.

Best For: Fashion-forward apparel, boutique brands, gifts, and premium custom tees with vintage or artistic designs.

Final Tips for Choosing the Right Fabric

• Consider the Use Case: Is it for daily wear, a concert, work, or a gift?
• Think About Climate: Cotton and tri-blends are better for warm weather; 50/50 blends offer versatility.
• Prioritize Comfort vs. Durability: Softness (tri-blend) vs. longevity (50/50 or cotton with care).
• Match Fabric to Print Style: Soft prints love tri-blends; bold logos stand out on 50/50 or cotton.

By weighing these factors, you can confidently select the perfect fabric for your custom t-shirts—balancing comfort, cost, and quality.

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, team, or event—but maximizing savings requires smart planning. By leveraging bulk quantity breaks and optimizing your artwork, you can significantly reduce per-unit costs without sacrificing quality. Here’s how.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order volume. The more shirts you order, the lower the price per unit. Typical quantity breaks include:

• 12–24 pieces
• 25–49 pieces
• 50–74 pieces
• 75–99 pieces
• 100+ pieces

Pro Tip: Always ask for a price quote at each tier. Jumping from 48 to 50 shirts may drop your per-shirt cost by 20–30%, so it’s often worth ordering slightly more to hit the next breakpoint.

Choose the Right Printing Method

The printing method impacts both cost and quality. Match your design and quantity needs to the best technique:

• Screen Printing: Ideal for large orders (50+ units) with simple designs and limited colors. Low per-unit cost after setup.
• DTG (Direct-to-Garment): Best for detailed, full-color designs or small batches. Higher per-shirt cost, but no setup fees.
• Dye Sublimation: Great for all-over prints on polyester fabrics. Cost-effective for complex designs in bulk.

For maximum savings, go with screen printing when possible—especially for high-volume orders.

Simplify Your Design to Reduce Costs

Complex designs increase printing costs. To save money:

• Limit the number of ink colors (each color requires a separate screen).
• Use vector-based artwork (scalable without quality loss).
• Avoid gradients and fine details that may require halftones or special techniques.

Design Tip: Many printers charge extra for more than 3–5 ink colors. A 1- or 2-color design can cut screen setup fees and speed up production.

Prepare Print-Ready Artwork

Poor artwork leads to extra fees and delays. Follow these best practices:

• File Format: Provide vector files (AI, EPS, or SVG) for logos and text. Use high-resolution PNG or TIFF (300 DPI) for raster images.
• Color Mode: Use CMYK or Pantone (PMS) colors as specified by your printer.
• Bleed and Safe Zones: Keep critical elements (text, logos) at least 0.5″ from garment edges.

Sending print-ready files reduces the need for design corrections, which can incur additional charges.

Order All Shirts at Once

Splitting a large order into multiple small batches increases costs due to repeated setup fees. Consolidate your order—even if you don’t need all shirts immediately—to lock in bulk pricing and avoid future price increases.

Compare Multiple Suppliers

Don’t settle for the first quote. Get bids from at least 3–5 reputable suppliers. Compare not just price, but also:

• Turnaround time
• Minimum order requirements
• Fabric and brand options
• Customer reviews

Online marketplaces like Custom Ink, Printful, or local screen printers may offer competitive pricing—especially during seasonal promotions.

Consider Shirt Quality and Brand

Basic cotton tees (e.g., Gildan, Hanes) are cheaper than premium brands (Bella+Canvas, Next Level). For bulk orders, standard fabric often provides the best value. Discuss blank shirt options with your printer—you might save 10–20% by choosing a cost-effective blank.

Use Promo Codes and Off-Season Discounts

Many printers offer seasonal discounts (e.g., back-to-school, holiday promotions). Sign up for newsletters or follow companies on social media to catch limited-time deals. Some also offer first-time customer discounts or referral bonuses.

Final Tips for Maximum Savings

• Bundle services: Some companies reduce costs if you use their design help and printing together.
• Negotiate: For very large orders (500+), ask for a custom quote—you may get additional discounts.
• Plan ahead: Rush fees can double your cost. Allow 2–3 weeks for production and shipping.

By combining smart design choices with strategic ordering, you can achieve high-quality custom t-shirts at the lowest possible price.