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

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

When designing custom running t-shirts, selecting the right fabric is crucial for comfort, performance, and durability. The material impacts moisture management, breathability, fit, and overall wearability during physical activity. Here’s a breakdown of three common fabric choices—100% Cotton, 50/50 Blend, and Tri-blends—to help you make the best decision for your custom running gear.

100% Cotton: Classic Comfort, But Not Ideal for Running

Pros:
– Soft, natural feel against the skin
– Breathable in moderate conditions
– Hypoallergenic and gentle for sensitive skin
– Readily available and often lower cost

Cons:
– Absorbs and retains sweat, leading to heavy, clingy fabric during runs
– Slow drying—can stay wet for long periods
– Prone to shrinking and losing shape after repeated washings
– Offers minimal stretch, which can restrict movement

Best For: Casual wear or post-run lounging—not recommended as a primary fabric for performance running.

50/50 Blend: A Balanced Middle Ground

Pros:
– Combines the softness of cotton with the durability and moisture-wicking properties of polyester
– More breathable and quicker drying than 100% cotton
– Resists shrinking and holds shape better than cotton alone
– Affordable and widely available

Cons:
– Still absorbs some moisture—may feel damp during intense workouts
– Less breathable and stretchy compared to performance synthetics
– Can develop odor over time if not treated with antimicrobial finishes

Best For: Light jogging or low-intensity runs, especially in mild weather. A good budget-friendly option for casual running events or charity races.

Tri-blends: Premium Performance and Comfort

Pros:
– Typically made from a mix of polyester, rayon, and cotton (e.g., 50% polyester, 25% cotton, 25% rayon)
– Excellent moisture-wicking and quick-drying capabilities
– Lightweight, soft, and drapes beautifully on the body
– Offers subtle stretch for improved mobility
– Resists shrinking and maintains shape well

Cons:
– Slightly higher cost than cotton or 50/50 blends
– May be less durable over time with frequent high-heat washing
– Rayon content can be more delicate—requires gentle care

Best For: Serious runners and performance-oriented apparel. Ideal for races, training sessions, and custom shirts designed for both comfort and style.

Final Considerations

• Performance Needs: For high-intensity or long-distance running, prioritize moisture-wicking, lightweight fabrics—tri-blends or performance polyester blends are best.
• Climate: In hot, humid conditions, avoid 100% cotton. Opt for tri-blends or 50/50s with good breathability.
• Care & Longevity: Consider how the shirts will be washed and worn. Tri-blends offer comfort but need gentle care; 50/50 blends are more forgiving.
• Aesthetic & Feel: Tri-blends have a soft, vintage look and luxurious drape. Cotton feels traditional, while 50/50s offer a balanced texture.

Conclusion: While 100% cotton is comfortable off the track, it’s not ideal for running. A 50/50 blend offers a practical compromise, but tri-blend fabrics deliver the best balance of performance, comfort, and style for custom running t-shirts. Choose based on your runners’ needs, budget, and intended use.

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

Ordering custom running t-shirts in bulk can be a cost-effective way to outfit your team, event, or brand. To maximize savings and ensure high-quality results, focus on strategic ordering and efficient artwork preparation.

Leverage Bulk Quantity Breaks

Most screen printers and apparel suppliers offer tiered pricing based on order volume. Understanding and optimizing these quantity breaks is key to securing the best price.

• Know the Break Points: Common quantity tiers are 12, 24, 36, 48, 72, 100, 250, and 500 units. Prices per shirt typically drop significantly at each breakpoint. For example, ordering 100 shirts may cost $12 each, but 250 could reduce the price to $8 each.

• Order Just Above the Breakpoint: If you need 90 shirts, consider ordering 100. The cost per unit will likely be lower, and you’ll have extras for replacements or future use.

• Combine Orders: Coordinate with other teams or clubs to combine orders and reach higher quantity tiers collectively.

• Negotiate Larger Orders: For orders over 500 units, contact suppliers directly to negotiate custom pricing. Larger runs often open doors to volume discounts and better fabric or printing options.

Optimize Artwork for Cost Efficiency

Your design choices directly impact production costs. Simplifying artwork reduces setup fees and printing time.

• Limit Print Colors: Each additional ink color increases screen setup and printing costs. Stick to 1–3 colors whenever possible. For example, a single-color logo is significantly cheaper than a full-color photographic print.

• Use Vector Art: Provide artwork in vector format (AI, EPS, or PDF). Vector graphics ensure crisp, scalable prints and are required by most professional printers. Avoid low-resolution JPEGs or PNGs.

• Simplify Design Complexity: Minimize fine details, gradients, and halftones, which can be challenging and costly to reproduce accurately. Clean, bold designs print better and cheaper.

• Standard Placement: Choose standard print locations like center chest, left chest, or back upper center. Off-center or multi-panel prints may incur additional fees.

• Reuse Designs: If reordering in the future, keep your original artwork files. Reusing designs avoids recreation fees and ensures consistency.

Additional Cost-Saving Tips

• Choose Mid-Range Apparel: High-performance technical fabrics (e.g., moisture-wicking polyester) are ideal for running, but premium brands cost more. Balance quality and budget by selecting reliable mid-tier brands with good performance features.

• Compare Multiple Suppliers: Get quotes from at least 3–5 reputable custom apparel printers. Include details like shirt style, quantity, print colors, and locations for accurate comparisons.

• Plan Ahead: Rush orders often come with 25–50% surcharges. Place your order well in advance of your event or race date.

• Bundle Services: Some suppliers offer package deals that include design assistance, free setup, or discounted extras like hats or bags when ordering large shirt quantities.

By strategically using bulk pricing tiers and preparing print-ready, simplified artwork, you can significantly reduce costs while still delivering professional-quality custom running t-shirts.