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

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|————————-|———————————————|———————————————|——————————————–|
| Best For | Large orders, simple designs, vibrant colors | Small orders, detailed/full-color designs | Small batches, quick turnaround, DIY use |
| Setup Time/Cost | High (per color setup) | Low (no setup needed) | Low to moderate (design prep) |
| Print Quality | High (durable, vibrant, consistent) | High (photo-quality, soft feel) | Moderate (can feel stiff, may peel) |
| Color Detail | Limited by number of screens/colors | Excellent (unlimited colors, gradients) | Excellent (full-color, photo-realistic) |
| Fabric Compatibility| Best on 100% cotton; limited on blends | Works on cotton and some blends (60%+) | Works on cotton, polyester, blends, and more |
| Durability | Extremely durable, long-lasting | Good, but may fade faster over time | Varies; prone to cracking/peeling over time|
| Cost Efficiency | Cost-effective for large runs | Cost-effective for small runs (1–20 pcs) | Low upfront cost, higher per-unit cost |
| Eco-Friendliness | Moderate (ink and cleaning chemicals) | Higher (water-based inks, less waste) | Lower (plastic-based transfers, energy use)|
| Production Speed | Fast for bulk after setup | Slower per item, good for on-demand | Fast for small batches, manual process |
| Ideal Use Cases | Bulk merch, logos, solid-color designs | Art prints, photos, complex artwork | Custom names/dates, sportswear, samples |
| Minimum Order | High (usually 25+ units) | Low (1+ units) | Very low (1+ units) |

Note: Performance can vary based on equipment, inks, and application techniques.

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

When designing custom t-shirts, choosing the right fabric is crucial—not just for comfort and durability, but also for how your design will look and last over time. The three most common fabric types are 100% cotton, tri-blends, and polyester, each with distinct characteristics. Here’s a breakdown to help you decide which is best for your needs.

100% Cotton

Pros:
– Soft and breathable: Cotton is naturally soft, especially after a few washes, and allows air to circulate, making it ideal for everyday wear.
– Comfortable: Offers a classic, familiar feel that many people prefer.
– Great for printing: Absorbs ink well, making it excellent for screen printing and DTG (direct-to-garment) printing.
– Eco-friendly option: Biodegradable and renewable, especially if organic cotton is used.

Cons:
– Prone to shrinking: Especially if not pre-shrunk, cotton can shrink in the dryer.
– Less durable over time: Can pill or wear out faster with frequent washing.
– Wrinkles easily: Requires ironing if a crisp look is desired.

Best For: Casual wear, promotional tees, eco-conscious brands, and designs that require vibrant, detailed prints.

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

Pros:
– Ultra-soft feel: The blend creates a smooth, lightweight fabric with a slightly heathered look.
– Drapes well: Offers a more fitted, flattering silhouette compared to 100% cotton.
– Resists shrinking and wrinkling: More stable than cotton alone.
– Breathable with stretch: The rayon adds softness and drape, while polyester adds durability and shape retention.

Cons:
– More expensive: Higher cost due to the blend and manufacturing process.
– Can be delicate: May be more prone to snagging or pilling with rough use.
– Printing nuances: May require special inks or settings for best results due to fabric composition.

Best For: Fashion-forward tees, women’s cuts, premium apparel lines, and brands looking for a soft, vintage-inspired look.

Polyester

Pros:
– Durable and long-lasting: Resistant to shrinking, stretching, and wrinkles.
– Moisture-wicking: Ideal for athletic or performance wear, keeping the wearer dry.
– Colorfast: Holds dyes well and resists fading over time.
– Lightweight and quick-drying: Great for activewear or outdoor events.

Cons:
– Less breathable: Can feel clammy or hot in warm weather.
– Prone to odor retention: Traps sweat and bacteria more than natural fibers.
– Can feel synthetic: Some people find polyester less comfortable against the skin.
– Shiny appearance: May not have the matte look preferred in casual tees.

Best For: Sports teams, workout gear, outdoor events, and sublimation printing (especially for all-over prints).

Choosing the Right Fabric

• For comfort and classic appeal: Choose 100% cotton.
• For a soft, stylish, premium feel: Go with a tri-blend.
• For performance, durability, and vibrant sublimated designs: Select polyester.

Consider your audience, use case, budget, and printing method when making your decision. The right fabric enhances both the look and longevity of your custom t-shirt.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, team, or event. However, maximizing savings requires smart planning, especially regarding order quantities and artwork preparation. Here’s how to get the best possible price.

Leverage Bulk Discounts Effectively

Bulk ordering is the single biggest way to reduce your per-unit cost. Suppliers offer tiered pricing, meaning the more you order, the less you pay per shirt. To take full advantage:

• Order Larger Quantities: Most printers offer significant savings at volume thresholds (e.g., 50+, 100+, 250+ units). Jumping from 48 to 50 pieces can drastically lower your price per shirt.
• Consolidate Orders: Instead of placing multiple small orders, combine needs across departments or events to reach higher volume tiers.
• Consider Standard Sizes: Ordering common sizes (like M, L, XL) in larger batches is often cheaper than spreading quantities across many sizes.
• Choose Simpler Shirt Options: Basic styles (e.g., Gildan 5000) are less expensive than premium or specialty fabrics (like tri-blends or organic cotton).
• Compare Suppliers: Use online quote tools from multiple bulk printers to find the best rates for your quantity and style.

Optimize Artwork to Reduce Printing Costs

The complexity of your design directly impacts the final cost. Streamlining your artwork can save money—especially with screen printing, where setup fees apply per color.

• Limit the Number of Colors: Each color requires a separate screen and setup. Designs with 1–3 colors are significantly cheaper than those with 5 or more.
• Use Vector Art: Always provide artwork in vector format (AI, EPS, or PDF). Vector files scale perfectly and are required for professional printing, avoiding costly recreation fees.
• Simplify Your Design: Avoid fine details, gradients, or complex shading. Bold, clean graphics print better and require fewer screens.
• Choose the Right Print Method:
• Screen Printing: Best for large orders with few colors (cost-effective at scale).
• DTG (Direct-to-Garment): Better for small runs or full-color designs, but more expensive per unit.
• Avoid All-Over Prints: Full-shirt designs increase ink use, print time, and cost. Stick to standard print locations (front, back, sleeve).
• Provide Print-Ready Files: Ensure your artwork is properly sized, centered, and in the correct color mode (CMYK or Pantone, not RGB).

By combining smart bulk ordering with professionally prepared, simplified artwork, you can achieve high-quality custom t-shirts at the lowest possible price. Plan ahead, get multiple quotes, and communicate clearly with your printer to maximize savings.