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

Note: True sublimation printing is not listed here as it requires polyester-based fabrics and a different process. The methods above are commonly compared when selecting techniques for custom t-shirts, but none are sublimation itself. Heat transfer is often confused with sublimation, but they are distinct processes.

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

When creating custom sublimation t-shirts, selecting the right fabric is crucial for achieving vibrant, long-lasting prints and a comfortable, high-quality final product. Not all fabrics are equally suited for sublimation printing. Here’s a breakdown of the most common fabric options—100% Cotton, 50/50 Blends, and Tri-blends—and how they perform with sublimation.

100% Cotton: Not Ideal for Sublimation

While 100% cotton is soft, breathable, and widely loved for its comfort, it is not suitable for traditional dye sublimation printing. Sublimation requires the dye to bond with polyester fibers at a molecular level through heat and pressure. Since cotton is a natural fiber that lacks polyester content, the sublimation ink will not adhere properly.

• Print Quality: Poor—inks sit on the surface rather than bonding, resulting in faded, blotchy prints that wash out quickly.
• Durability: Very low—designs degrade rapidly after washing.
• Best For: Direct-to-garment (DTG) printing, screen printing, or other methods designed for cotton.
• Sublimation Alternative: Use 100% cotton only if you’re employing a sublimation coating or special transfer paper designed for cotton (not traditional sublimation).

50/50 Blend (Cotton/Polyester): Limited Sublimation Use

A 50/50 blend combines cotton and polyester, offering a balance of softness and durability. However, with only 50% polyester content, it’s still not ideal for standard sublimation.

• Print Quality: Moderate to poor—prints may appear faded or less vibrant due to the lower polyester content.
• Durability: Fair—designs may fade over time, especially after repeated washings.
• Best For: Garments where softness is a priority, but a full sublimation look isn’t required. Some specialty sublimation transfers (like hybrid transfer papers) can work on 50/50 blends with limited success.
• Sublimation Tip: If using a 50/50 blend, expect softer, vintage-style prints rather than bold, photo-quality results.

Tri-blends (Typically Poly/Cotton/Rayon): Excellent for Sublimation

Tri-blend fabrics—usually a combination of polyester, cotton, and rayon (e.g., 50% poly, 25% cotton, 25% rayon)—are among the best choices for sublimation printing when properly constructed.

• Print Quality: Excellent—high polyester content allows for vibrant, detailed, and full-color designs that are permanently infused into the fabric.
• Durability: High—prints resist fading and cracking even after many washes.
• Feel & Drape: Soft, lightweight, and slightly heathered with a luxurious, vintage-like texture that’s popular in premium apparel.
• Best For: Fashion-forward tees, retail apparel, and custom merchandise where comfort and print quality are both priorities.
• Important Note: Ensure the tri-blend has sufficient polyester (ideally 50% or more) for successful sublimation. Always pre-test with your specific fabric and printer.

Conclusion: Choose Polyester-Rich Fabrics for Best Results

For successful sublimation t-shirts, avoid 100% cotton and 50/50 blends if you want bold, durable prints. Instead, opt for tri-blend fabrics with high polyester content or 100% polyester performance fabrics. Tri-blends offer the ideal balance of print vibrancy, softness, and drape—making them the top choice for high-quality custom sublimation apparel. Always test your materials first to ensure compatibility with your sublimation process.

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

Getting high-quality custom sublimation t-shirts at the best possible price requires smart planning—especially when ordering in bulk. Below are key strategies to maximize your savings on quantity breaks and ensure your artwork enhances cost-efficiency.

Maximize Bulk Quantity Breaks

Suppliers typically offer lower per-unit pricing as your order quantity increases. To take full advantage:

• Order at Tier Thresholds: Most printers have pricing tiers (e.g., 50, 100, 250, 500+ units). Ordering just above the threshold (e.g., 101 instead of 99) can save significantly. Always ask for a pricing sheet to identify these breakpoints.
• Consolidate Designs: If you need multiple designs, consider standardizing colors or layouts across shirts. Fewer unique designs reduce setup and printing complexity, which can lower costs.
• Commit to Larger Runs: If future demand is predictable, order more upfront. Storage is often cheaper than paying higher per-unit prices on smaller repeat orders.
• Negotiate with Suppliers: For very large orders (500+), contact sales reps directly to negotiate custom pricing, especially if you’re a repeat customer or part of an organization.

Optimize Artwork to Reduce Costs

Your design file quality and format play a big role in production efficiency and final cost:

• Use High-Resolution Files: Submit artwork at 300 DPI in vector format (AI, EPS, SVG) or high-res PNG/TIFF. Low-quality images may require designer cleanup—often billed as an extra fee.
• Design Within the Print Area: Stick to standard print dimensions (e.g., 12″x14″ for front prints) to avoid custom masking or trimming, which can increase labor costs.
• Limit Color Complexity: Sublimation prints all colors in one pass, but overly complex gradients or tiny details can lead to reprints if misaligned. Simplified, bold designs are more reliable and cost-effective.
• Provide Transparent Backgrounds: Always submit designs with transparent backgrounds (PNG or layered PSD). This prevents unwanted borders or cropping issues that could lead to reprints.
• Proof Before Printing: Request a digital proof to catch errors early. Fixing mistakes post-production adds cost and delays.

By combining strategic bulk ordering with print-ready artwork, you’ll not only get the best price but also ensure faster turnaround and higher-quality results. Always get quotes from multiple suppliers and ask about volume discounts and artwork requirements upfront.