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

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

Selecting the right fabric is crucial for the look, feel, durability, and print quality of your custom screen printed t-shirts. Three of the most popular options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s a breakdown to help you decide which is best for your project.

100% Cotton: Classic Comfort and Softness

Pros:
– Soft, Natural Feel: Offers a breathable, comfortable, and familiar feel against the skin.
– Excellent Ink Absorption: Cotton fibers readily absorb water-based and plastisol inks, resulting in vibrant, crisp prints with a slightly softer hand feel.
– Great for Vintage or Retro Looks: Prone to slight shrinkage and natural fading over time, which can enhance a worn-in, authentic aesthetic.
– Eco-Friendly Option: Biodegradable and often preferred for sustainable apparel lines.

Cons:
– Prone to Shrinkage: Can shrink significantly (up to 5–10%) after washing, especially if not pre-shrunk. Consider garment specs carefully.
– Less Durable: More susceptible to pilling, wear, and tear compared to blended fabrics.
– Wrinkles Easily: Requires more ironing or steaming for a crisp appearance.
– Absorbs Moisture: Can feel damp or heavy when sweaty, making it less ideal for active wear.

Best For: Everyday casual wear, eco-conscious brands, vintage-inspired designs, and customers who prioritize softness and natural fibers.

50/50 Cotton-Polyester Blend: The Balanced Performer

Pros:
– Reduced Shrinkage: The polyester content helps stabilize the fabric, minimizing shrinkage after laundering.
– Increased Durability: More resistant to pilling, stretching, and general wear than 100% cotton.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Moisture-Wicking (Slight): Polyester helps draw moisture away from the skin, enhancing comfort during light activity.
– Cost-Effective: Often priced between cotton and tri-blends, offering good value.

Cons:
– Less Soft Than Cotton: Can feel slightly stiffer or less breathable, especially in warmer climates.
– Ink Adhesion Challenges: Polyester can resist water-based inks; plastisol is typically used and may sit more on the surface, resulting in a slightly firmer print hand.
– Prone to Static: Can generate static electricity, attracting lint or dust.
– Pilling Over Time: While better than cotton, lower-quality 50/50 blends may still pill with extended wear.

Best For: Promotional apparel, workwear, school events, or any application where durability, consistent sizing, and moderate comfort are priorities.

Tri-blends: The Premium Soft and Stylish Choice

Typical Composition: 50% polyester, 25% cotton, 25% rayon (viscose)

Pros:
– Ultra-Soft Hand Feel: Rayon adds a silky, luxurious softness that drapes beautifully—often compared to a vintage tee.
– Excellent Drape: Flatters the body with a relaxed, slightly fitted look.
– Minimal Shrinkage: Polyester and rayon content reduce shrinkage compared to 100% cotton.
– Breathable and Lightweight: Ideal for warmer weather and layering.
– Unique Vintage Aesthetic: Develops a slightly heathered, lived-in look over time, perfect for fashion-forward designs.

Cons:
– Higher Cost: Typically the most expensive of the three options.
– Delicate Fabric: Less durable than cotton or 50/50 blends; can snag or tear more easily.
– Printing Challenges: Rayon can be sensitive to heat, so curing temperatures must be carefully controlled. Ink may bleed slightly if not handled properly.
– Color Fading: Some tri-blends may fade faster, especially in sunlight.

Best For: Fashion brands, boutique apparel, women’s tees, premium gift items, and designs that benefit from a soft drape and vintage appeal.

Making the Right Choice

• Prioritize Comfort & Natural Feel? → Choose 100% Cotton
• Need Durability & Consistent Sizing? → Choose 50/50 Blend
• Want Premium Softness & Fashionable Drape? → Choose Tri-blend

Always consider your target audience, intended use, budget, and design style when selecting your fabric. Ordering samples is highly recommended to feel the differences firsthand before placing a large print order.

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

Ordering custom screen-printed t-shirts in bulk can be cost-effective, but to get the best price, you need to understand how pricing works and how to optimize your order. Here’s how to save money using bulk quantity breaks and smart artwork practices.

Leverage Bulk Quantity Breaks

Screen printing companies typically offer tiered pricing based on the number of shirts ordered. The more you order, the lower the per-unit cost.

• Know the Standard Quantity Tiers: Common breaks include 12, 24, 36, 48, 72, 100, 250, and 500+ units. Ordering just above a break (e.g., 251 instead of 249) can significantly reduce your price per shirt.
• Consolidate Orders: Combine multiple smaller orders from your team, event, or group into one large order to reach a higher tier.
• Plan Ahead: Forecast your needs and order in advance to take advantage of bulk pricing, even if you don’t need all shirts immediately.

Choose the Right Shirt Style and Color

• Opt for Basic, Popular Styles: Common brands like Gildan, Hanes, or Bella+Canvas are cheaper than premium options.
• Stick to Light-Colored Shirts: White or light-colored garments require less ink and are cheaper to print on, especially for dark or vibrant designs.
• Limit Color Variants: Ordering all shirts in one or two colors reduces setup time and cost.

Optimize Your Artwork for Cost Efficiency

The complexity of your design directly impacts printing costs.

• Limit Print Colors: Each additional ink color requires a separate screen and setup fee. Stick to 1–3 colors to keep costs low.
• Use Vector Art: Provide high-resolution vector files (AI, EPS, or SVG) to avoid artwork conversion fees and ensure clean printing.
• Simplify Your Design: Avoid gradients, fine details, or halftones that increase setup complexity. Bold, clean graphics print better and cheaper.
• One-Location Printing: Print on just one spot (e.g., front center) instead of multiple locations (front, back, sleeve) to reduce labor and setup.

Work With the Right Printer

• Get Multiple Quotes: Compare prices from 3–5 reputable screen printers. Be sure quotes include all fees (setup, screens, art, shipping).
• Ask About Setup Fees: Some printers waive or reduce setup fees for large orders or repeat customers.
• Check for Promotions: Look for seasonal discounts, first-time customer deals, or referral programs.

Final Tips for Saving Money

• Avoid Rush Fees: Give yourself plenty of lead time—rushed orders can double printing costs.
• Bundle Sizes and Colors: If you need multiple sizes, distribute them across your total order evenly. Avoid very small or very large sizes unless necessary, as they can cost more.
• Request a Physical Sample: Before full production, order a sample to check print quality and avoid costly reprints.

By leveraging bulk quantity breaks, simplifying your design, and choosing the right materials and printer, you can get high-quality custom screen-printed t-shirts at the best possible price.