Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Fabric Guide for Custom T-Shirt Companies

Choosing the right fabric is one of the most important decisions a custom t-shirt company makes. It directly impacts comfort, durability, print quality, appearance, and customer satisfaction. Understanding the key differences between popular fabric types—100% cotton, 50/50 blends, and tri-blends—helps you offer the best options for your clients’ needs.

100% Cotton

100% cotton t-shirts are the classic choice, prized for their softness, breathability, and natural feel.

Pros:
– Soft & Comfortable: Feels great against the skin, especially after a few washes.
– Breathable: Excellent moisture absorption and air circulation, ideal for warm weather.
– Eco-Friendly: Made from a natural, renewable resource; biodegradable.
– Great for Printing: Holds vibrant prints well, especially with screen printing and direct-to-garment (DTG) methods.
– Easy to Dye: Takes dyes evenly, resulting in rich, consistent colors.

Cons:
– Prone to Shrinkage: Can shrink significantly (up to 5-7%) if not pre-shrunk.
– Less Durable: More susceptible to wear, pilling, and stretching over time.
– Wrinkles Easily: Requires frequent ironing to maintain a crisp look.
– Slower Drying: Takes longer to dry compared to synthetic blends.

Best For: Casual wear, eco-conscious customers, screen printing, promotional events, and customers who prefer a traditional t-shirt feel.

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

The 50/50 blend combines the best of both worlds—cotton’s comfort and polyester’s durability.

Pros:
– Reduced Shrinkage: Resists shrinking better than 100% cotton.
– More Durable: Withstands repeated washing and wear with less pilling.
– Faster Drying: Polyester wicks moisture and dries quickly.
– Retains Shape: Less likely to stretch out or lose its form.
– Affordable: Often priced competitively, making it a cost-effective option.

Cons:
– Less Breathable: Polyester can trap heat and feel less airy than pure cotton.
– Slightly Less Soft: May feel rougher or less natural initially (though modern versions are much improved).
– Prone to Pilling: Over time, especially with friction, small fabric balls may form.
– Printing Challenges: Can be trickier for DTG printing due to polyester content; may require pretreatment.

Best For: Workwear, school uniforms, sports teams, high-turnover promotional items, and customers seeking a balance of comfort and durability.

Tri-Blends (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Tri-blend fabrics offer a premium, soft, vintage-style feel that’s become increasingly popular.

Pros:
– Exceptionally Soft: Feels buttery smooth and lightweight, often described as “fitted” or “athleisure”-style.
– Vintage Aesthetic: Fades slightly with wear, giving shirts a worn-in, fashion-forward look.
– Great Drape: Flatters the body with a softer, more fluid silhouette.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic fibers.
– Moisture Wicking: Polyester and rayon help manage sweat effectively.

Cons:
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Less Durable: Rayon can weaken when wet and may wear faster with heavy use.
– Delicate Care Required: Often requires gentle washing and avoiding high heat.
– Printing Sensitivity: Rayon content can be sensitive to high heat during printing; requires precise settings.

Best For: Fashion-forward brands, boutique apparel, yoga/streetwear, music festivals, and customers who value softness and a modern, relaxed look.

Choosing the Right Fabric for Your Custom T-Shirt Business

When selecting fabrics, consider:
– Your Target Market: Are they eco-conscious, athletic, fashion-focused, or budget-oriented?
– Intended Use: Is the shirt for daily wear, sports, events, or promotional giveaways?
– Printing Method: DTG, screen printing, and sublimation each interact differently with fabric types.
– Budget: Balance quality with pricing strategy and customer expectations.
– Sustainability Goals: Offer organic cotton or recycled polyester options for eco-minded clients.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, your custom t-shirt company can deliver products that meet both performance and customer satisfaction goals.

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

Understanding Bulk Quantity Breaks

When ordering custom t-shirts in bulk, one of the most effective ways to reduce your cost per unit is by leveraging quantity breaks. Most custom t-shirt companies offer tiered pricing, where the more shirts you order, the lower the price per shirt.

Key Tips:

• Order at Tier Thresholds: Prices typically drop at specific quantities (e.g., 50, 100, 250, 500). Ordering just above these thresholds (like 101 instead of 99) can save money.
• Consolidate Designs: If you’re ordering multiple designs, combine them into a single order if possible. Larger total quantities often qualify for better pricing.
• Plan Ahead: Forecast your needs to maximize volume discounts. Consider future events or team needs to increase order size.

Choose the Right T-Shirt Style and Material

Not all shirts cost the same. Basic cotton tees are cheaper than premium blends or specialty fabrics.

Cost-Saving Tips:

• Opt for standard weights (e0.g., 5.3 oz cotton) instead of heavy or organic materials unless necessary.
• Stick to popular colors like black, white, or navy. Specialty colors may incur dye charges.
• Use value-priced brands like Gildan, Hanes, or Bella+Canvas 3001, which offer quality at lower costs.

Simplify Your Design to Reduce Printing Costs

The complexity of your artwork directly affects the price. Printing companies charge more for multi-color designs, large prints, and special techniques.

Artwork Tips to Save Money:

• Limit Screen Colors: Each color in a design requires a separate screen. Stick to 1–3 colors for the lowest prices in screen printing.
• Use Simpler Designs: Avoid gradients, fine details, or photographic images—they increase setup time and cost.
• Optimize Print Location: One print location (e.g., front only) is cheaper than multiple locations (front + back + sleeve).

Prepare Print-Ready Artwork

Submitting high-quality, properly formatted artwork reduces setup fees and delays.

Artwork Best Practices:

• Provide vector files (AI, EPS, or SVG) for crisp, scalable logos.
• Use high-resolution PNG or JPEG (at least 300 DPI) if vector isn’t available.
• Specify Pantone (PMS) colors to ensure color accuracy and avoid extra color matching fees.
• Confirm print size and placement with the vendor before finalizing.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote. Compare prices across several reputable suppliers.

Smart Sourcing Strategies:

• Use online tools from companies like Custom Ink, Printful, or T-shirt Elephant to compare instant pricing.
• Ask about promotions, student discounts, or nonprofit pricing.
• Negotiate with local or regional printers—they may match or beat online prices for bulk orders.

Consider Printing Method

Different printing techniques affect cost and quality.

Cost vs. Method:

• Screen Printing: Most cost-effective for large quantities (50+ units) and simple designs.
• DTG (Direct-to-Garment): Better for complex, full-color designs or small batches—but higher per-unit cost.
• Heat Transfer or Vinyl: Good for very small runs or names/numbers, but less durable and not ideal for bulk.

Final Tips for the Best Deal

• Avoid Rush Fees: Place orders well in advance to skip expedited processing charges.
• Bundle Accessories: Some companies offer discounts if you also order hats, hoodies, or bags.
• Request Samples: Order a sample first to check quality—avoid costly reprints due to errors.

By combining smart bulk ordering, efficient artwork, and strategic vendor selection, you can significantly reduce costs while still getting high-quality custom t-shirts.