Screen Printing vs. DTG vs. Heat Transfer: Custom T-Shirt Printing Comparison

| Feature | Screen Printing | DTG (Direct-to-Garment) | Heat Transfer |
|————————–|——————————————|—————————————–|——————————————|
| Best For | Large orders, simple designs, vibrant colors | Small orders, detailed/photographic designs | Small runs, quick turnaround, DIY projects |
| Setup Time & Cost | High (requires screens per color) | Low (minimal setup) | Low to medium (design prep & transfer) |
| Print Quality | High (bold, opaque, durable) | High (photo-realistic, soft feel) | Medium (can feel plasticky, may crack) |
| Fabric Compatibility | Works on cotton, polyester, blends | Best on 100% cotton; limited on blends | Works on most fabrics including polyester |
| Color Capability | Limited by number of screens/colors | Full-color (unlimited colors) | Full-color (unlimited colors) |
| Durability | Excellent (lasts many washes) | Good (may fade over time) | Fair to good (depends on transfer type) |
| Cost per Unit | Low for bulk orders | Higher per unit, consistent pricing | Low for small quantities |
| Minimum Order | Recommended 24+ units | As low as 1 unit | As low as 1 unit |
| Design Flexibility | Low (design changes require new screens) | High (easy design changes) | High (easy to swap designs) |
| Feel on Shirt | Slightly raised, thicker ink layer | Soft, absorbent (ink soaks into fabric) | Can be stiff or rubbery (especially cheap transfers) |
| Eco-Friendliness | Moderate (ink and screen cleaning waste) | Higher (water-based inks, less waste) | Low to moderate (plastic-based transfers) |
| Turnaround Time | Medium to long (setup required) | Fast for small batches | Very fast (ideal for on-demand) |
| Common Use Cases | Band tees, sports teams, promotional merch | Art prints, custom photos, small shops | Retail customization, events, samples |

Summary:
– Screen Printing excels in durability and cost-efficiency for large, simple designs.
– DTG is ideal for detailed, full-color artwork on cotton garments with no minimums.
– Heat Transfer offers speed and flexibility for small batches and mixed fabrics but may compromise on feel and longevity.

Guide to Choosing Fabrics for Custom T-Shirts: 100% Cotton vs. Tri-Blends vs. Polyester

When designing custom t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and print quality. Understanding the key differences between 100% cotton, tri-blends, and polyester will help you select the best option for your needs.

100% Cotton

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warmer weather, due to its natural fibers and breathability.
– Great for Printing: Absorbs ink well, making it ideal for screen printing and DTG (direct-to-garment) printing with vibrant, long-lasting results.
– Natural Feel: Preferred by many for its classic, soft hand feel and eco-friendly appeal (if organic cotton is used).

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster over time and is more susceptible to pilling.
– Wrinkles Easily: Requires ironing for a crisp look.

Best For: Casual wear, everyday tees, vintage-style prints, and eco-conscious brands.

Tri-Blends (Typically Cotton, Polyester, and Rayon)

Pros:
– Ultra-Soft and Lightweight: Blends combine the softness of cotton, durability of polyester, and drape of rayon for a luxurious feel.
– Excellent Drape: Flatters the body with a slightly fitted, fashion-forward silhouette.
– Fade-Resistant: Holds color well over time, ideal for detailed or colorful designs.

Cons:
– Higher Cost: Generally more expensive than 100% cotton or polyester.
– Less Breathable: May not be as breathable as pure cotton in hot conditions.
– Slight Sheen: The rayon content can give a subtle sheen, which may not suit all design aesthetics.

Best For: Fashion tees, boutique brands, events, and soft-style prints with a modern look.

Polyester

Pros:
– Durable and Moisture-Wicking: Resistant to shrinking, stretching, and wrinkles. Ideal for activewear and performance tees.
– Quick-Drying: Excellent for sports or outdoor use due to its moisture management.
– Color Retention: Holds bright colors well, especially with dye-sublimation printing.

Cons:
– Less Breathable: Can feel clammy or hot in warm weather.
– Prone to Pilling: May develop small fabric balls over time with friction.
– Static and Odor Retention: Can retain odors and generate static electricity.

Best For: Athletic wear, promotional events, outdoor activities, and all-over prints using sublimation.

Choosing the Right Fabric

• Comfort & Casual Wear? → Go with 100% Cotton or Tri-Blend.
• Activewear or Performance? → Choose Polyester or a Poly-Cotton Blend.
• Vibrant, All-Over Design? → Polyester with dye-sublimation.
• Classic Look & Feel? → Stick with 100% Cotton.

Consider your audience, use case, and printing method to make the best fabric choice for your custom t-shirts.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To maximize your savings and ensure a great final product, focus on two key areas: leveraging bulk pricing and preparing your artwork correctly.

Take Advantage of Bulk Discounts

The most effective way to reduce the per-unit cost of custom t-shirts is by ordering in bulk. Most screen printers and online suppliers offer tiered pricing based on quantity.

• Order Larger Quantities: Prices typically drop significantly at volume thresholds like 50, 100, 250, or 500 units. For example, ordering 200 shirts may cost much less per shirt than ordering 50.
• Consolidate Orders: If different departments or teams need shirts, combine orders to reach a higher pricing tier.
• Plan Ahead: Buy more than you immediately need if storage allows—this locks in a lower rate and prevents future rush fees.

Choose the Right Printing Method

Different printing techniques vary in cost and quality. Select one that fits both your design and budget.

• Screen Printing: Most cost-effective for large orders (50+ units) with simple, bold designs. Setup costs are high, but per-unit cost drops with volume.
• Direct-to-Garment (DTG): Ideal for detailed, full-color designs or very small runs. Higher per-shirt cost, so less economical for bulk orders.
• Heat Transfer: Suitable for small batches or intricate designs, but less durable and not ideal for large quantities.

Optimize Artwork to Save Money and Time

Proper artwork preparation prevents delays, reprints, and extra charges.

• Use High-Resolution Files: Submit artwork at 300 DPI resolution in vector formats (AI, EPS, SVG) or high-res PNG/PDF. Low-quality images result in blurry prints and added correction fees.
• Simplify Your Design: Fewer colors mean lower screen printing costs. Each additional color requires a separate screen and setup fee.
• Stick to Standard Colors: Use standard ink colors instead of custom mixes, which can increase costs.
• Provide Clear Mockups: Include size guides and placement specifications (e.g., left chest, full back) to avoid misprints.

Compare Multiple Suppliers

Don’t settle for the first quote. Research and compare several vendors based on:

• Price per unit at your desired quantity
• Setup and art fees
• Shipping costs and turnaround time
• Minimum order requirements

Many online printers offer instant quotes—use these to quickly compare options.

Order Shirt and Print Colors Strategically

• Choose Basic Shirt Colors: White and black shirts are usually cheaper than fashion or specialty colors.
• Match Ink to Shirt: Light ink on dark shirts (and vice versa) may require an underbase, increasing cost. Opt for high-contrast combinations when possible.

By ordering in bulk, preparing clean artwork, and selecting the right printing method, you can significantly reduce your custom t-shirt costs without sacrificing quality.