Comparison Table: Screen Printing, DTG, and Heat Transfer for Custom T-Shirt Colors

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

When designing custom t-shirts, selecting the right fabric is just as important as the design itself. The fabric affects comfort, durability, appearance, and how well the colors and prints turn out. Here’s a breakdown of the three most popular fabric options—100% cotton, 50/50 blend, and tri-blends—to help you choose the best one for your custom t-shirt colors.

1. 100% Cotton

Best for: Classic comfort and soft hand feel
Absorbency: High
Durability: Good, but may shrink over time
Color Vibrancy: Excellent for vibrant prints, especially with water-based inks

100% cotton t-shirts are a timeless favorite. They’re breathable, soft, and ideal for screen printing. Because cotton readily absorbs ink, colors appear rich and true to design—perfect for bold logos and detailed artwork. However, pure cotton can shrink in the wash (especially if not pre-shrunk) and may wrinkle more easily. It’s best suited for standard, everyday wear where comfort is key.

2. 50/50 Blend (50% Cotton, 50% Polyester)

Best for: Durability and reduced shrinkage
Absorbency: Moderate
Durability: High
Color Vibrancy: Good; holds up well to repeated washing

The 50/50 blend combines the comfort of cotton with the resilience of polyester. These shirts resist shrinking and wrinkling better than 100% cotton, making them a popular choice for promotional apparel and workwear. Colors remain vibrant after multiple washes, and the fabric retains its shape. While slightly less breathable than pure cotton, the blend offers a good balance between softness and longevity—ideal for frequently worn or washed tees.

3. Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Best for: Softness, drape, and a vintage look
Absorbency: Low to moderate
Durability: Moderate; softer feel but may pill over time
Color Vibrancy: Subtle and muted; offers a heathered or retro appearance

Tri-blend fabrics are known for their ultra-soft, lightweight feel and excellent drape—often compared to a worn-in vintage tee. The inclusion of rayon gives these shirts a slight sheen and a smoother texture. When it comes to color, tri-blends produce a more muted, heathered effect, which is perfect for fashion-forward or lifestyle brands wanting a sophisticated, relaxed aesthetic. However, because of the polyester content, some printing methods may require adjustments to ensure ink adhesion and color accuracy.

Choosing the Right Fabric for Your Custom Colors

• For bright, crisp prints: Choose 100% cotton or 50/50 blend.
• For long-lasting wear and wash resistance: Opt for 50/50 blend.
• For a soft, stylish, vintage look: Go with tri-blend.

Consider your audience, use case, and desired aesthetic when selecting your fabric. Each material interacts differently with inks and dyes, so testing a sample print can help ensure your custom t-shirt colors look exactly as intended.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team—but maximizing savings requires smart planning. The key factors influencing your final price are order quantity, color selection, and artwork complexity. Here’s how to get the best deal without sacrificing quality.

Leverage Bulk Quantity Breaks

Most printing companies offer tiered pricing based on volume, meaning the more you order, the lower the per-unit cost. To take full advantage:

• Order in standard quantity brackets: Companies often have price breaks at 25, 50, 100, 250, and 500 units. Ordering just above a break (e.g., 101 instead of 100) rarely increases cost but can qualify you for a lower rate.
• Consolidate orders: If you anticipate needing shirts over time, place one large order instead of multiple small ones. Storage is cheaper than paying premium rates for low-volume prints.
• Mix sizes, not styles: Stick to one t-shirt brand and style across sizes (S, M, L, XL) to maintain bulk pricing. Switching styles resets the volume count.

Simplify Your T-Shirt Color Selection

The color of the blank t-shirt significantly affects printing costs:

• Choose standard colors: White or basic colors (black, navy, gray) are usually cheaper because they’re produced in higher volumes.
• Avoid specialty fabrics: Tri-blend, organic cotton, or performance fabrics cost more than standard 100% cotton.
• Opt for lighter colors when possible: Printing on dark shirts requires an underbase (white ink layer), increasing ink use and production time. Lighter shirts save money, especially with detailed designs.

Optimize Your Artwork for Cost-Efficiency

The complexity of your design directly impacts printing costs. A well-prepared artwork file reduces setup fees and speeds up production:

• Limit print colors: Each additional ink color increases setup and printing time. Stick to 1–3 colors to minimize costs. Use color blending techniques (like halftones) if needed.
• Use vector artwork: Provide high-resolution vector files (AI, EPS, or SVG) to avoid recreation fees. Raster images (JPEG, PNG) may require redrawing.
• Simplify your design: Avoid fine details or gradients that require advanced printing methods like DTG (Direct-to-Garment). Screen printing is cheaper for bold, solid-color designs.
• Stick to one print location: Printing on the front only is less expensive than front-and-back or sleeve prints. Each added location increases labor and setup.

Bonus Tips for Maximum Savings

• Get multiple quotes: Compare prices from at least 3–5 reputable suppliers. Some specialize in low minimums, others in high-volume discounts.
• Ask about package deals: Some vendors offer discounts when combining t-shirts with hats, bags, or other apparel.
• Watch for seasonal promotions: Many printers offer discounts during back-to-school, holiday, or end-of-quarter periods.

By strategically planning your order size, selecting cost-effective colors, and optimizing your artwork, you can significantly reduce the per-unit price of custom t-shirts—without compromising on quality or impact.