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

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

Selecting the right fabric is a critical decision for any custom t-shirt company. It directly impacts customer satisfaction, durability, print quality, and overall brand perception. Understanding the differences between popular fabric types—100% cotton, 50/50 blends, and tri-blends—will help you offer the best products for your target market. Here’s a detailed comparison to guide your choice.

100% Cotton

What It Is: Made entirely from natural cotton fibers, this classic fabric is soft, breathable, and widely loved.

Pros:
– Natural Feel: Offers a soft, comfortable hand feel that many customers prefer.
– Breathability: Excellent for warm weather and active wear due to high air permeability.
– Print Quality: Absorbs inks well, making it ideal for vibrant screen printing and detailed designs.
– Hypoallergenic: Less likely to irritate sensitive skin.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.

Cons:
– Shrinkage: Prone to shrinking if not pre-shrunk (pre-shrunk cotton is recommended).
– Wrinkling: Wrinkles easily and may require ironing.
– Durability: Less resistant to wear and tear over time compared to blended fabrics.
– Moisture Retention: Absorbs sweat but dries slowly.

Best For: Casual wear, eco-conscious brands, screen-printed promotional shirts, and customers who value natural fabrics.

50/50 Cotton-Polyester Blend

What It Is: A balanced blend of 50% cotton and 50% polyester, combining the best qualities of both fibers.

Pros:
– Durability: More resistant to wear, shrinking, and fading than 100% cotton.
– Wrinkle Resistance: Holds its shape better and resists wrinkles.
– Cost-Effective: Often less expensive than 100% cotton or tri-blends.
– Moisture Wicking: Polyester helps wick moisture, keeping wearers drier.
– Consistent Shape: Holds its form after repeated washings.

Cons:
– Less Breathable: Not as breathable as 100% cotton, which may be less comfortable in hot climates.
– Texture: Can feel slightly synthetic or less soft compared to cotton or tri-blends.
– Pilling: May develop small fabric pills over time with friction.

Best For: Budget-friendly apparel, event t-shirts, workwear, and situations where durability and shape retention are priorities.

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

What It Is: A soft, lightweight fabric combining polyester, cotton, and rayon (often modal or viscose) for a luxurious feel.

Pros:
– Exceptional Softness: Known for a silky, vintage-inspired hand feel—often compared to a well-worn favorite tee.
– Drape: Flows nicely and conforms comfortably to the body.
– Fade Resistance: Blends well with dyes and resists fading over time.
– Lightweight: Ideal for layering and warmer climates.
– Minimal Shrinkage: Typically holds shape better than 100% cotton.

Cons:
– Higher Cost: More expensive due to the inclusion of rayon and complex manufacturing.
– Less Durable: May not withstand heavy use or frequent washing as well as cotton or 50/50 blends.
– Heat Sensitivity: Rayon can degrade under high heat, so low-heat washing and drying are recommended.
– Print Limitations: May require special inks or techniques for optimal print results.

Best For: Fashion-forward brands, premium apparel lines, lifestyle brands, and customers seeking a high-end, soft feel.

Choosing the Right Fabric for Your Brand

• For Value & Versatility: Offer 50/50 blends for affordable, durable t-shirts suitable for events, promotions, and everyday wear.
• For Comfort & Sustainability: Choose 100% cotton for a natural, breathable option that appeals to eco-conscious consumers.
• For Luxury & Style: Use tri-blends to create premium, soft garments that elevate your brand’s perceived value.

Pro Tip: Consider offering multiple fabric options to cater to different customer preferences and use cases. Clearly communicate the features of each fabric on your product pages to help buyers make informed choices.

By understanding these key fabric types, you can curate a product line that meets diverse customer needs while maintaining quality, comfort, and profitability.

How to Get the Best Price for a Custom T-Shirt Company (Bulk Quantity Breaks & Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, organize an event, or sell merchandise. However, to maximize your savings and ensure top-quality results, it’s important to understand pricing strategies and preparation requirements. Here’s how to get the best deal on your bulk custom t-shirt order.

Leverage Bulk Quantity Breaks

Most custom t-shirt companies offer tiered pricing based on order size, meaning the more shirts you order, the lower the price per unit. To take full advantage:

• Know the Break Points: Common quantity tiers are 50, 100, 250, and 500+ units. Ordering just above these thresholds (e.g., 101 instead of 99) can significantly reduce your cost per shirt.
• Consolidate Orders: If you’re part of a group or organization, combine orders with others to hit higher volume tiers.
• Plan for the Future: If you anticipate needing shirts later, order in larger quantities now to lock in lower rates and avoid rush fees down the line.
• Compare Vendors: Different companies have different break points and pricing structures. Use online quote tools to compare prices across multiple suppliers at the same volume levels.

Simplify Your Design to Save Money

The complexity of your artwork directly affects printing costs. Keep these artwork tips in mind:

• Limit Print Colors: Each additional ink color increases setup and printing time. Stick to one or two colors for the best pricing, especially with screen printing.
• Choose One-Sided Prints: Printing on both the front and back doubles your setup cost. Opt for a single-side design when possible.
• Use Vector Artwork: Provide high-resolution vector files (AI, EPS, or PDF) to avoid extra charges for design recreation or file corrections.
• Avoid Full-Color or Photo Prints (if budget-conscious): Full-color designs often require costly digital printing or simulated process printing. Simple designs with solid colors are more affordable with traditional screen printing.

Select the Right Printing Method

Different printing techniques impact cost and quality. Choose wisely based on your design and budget:

• Screen Printing: Most cost-effective for large orders with simple, bold designs. Ideal when using fewer ink colors.
• DTG (Direct-to-Garment): Better for detailed or full-color designs on smaller quantities, but higher per-unit cost.
• Embroidery: Great for logos on polos or hats, but generally more expensive than printing.

Choose Standard Shirt Options

Customization beyond the basics can drive up prices:

• Stick to Standard Colors and Styles: Basic shirt colors (black, white, navy) are usually cheaper and more readily available than specialty colors.
• Use One Shirt Type: Ordering all the same style and brand streamlines production and reduces setup costs.
• Avoid Add-Ons: Features like custom labels, tags, or special packaging can add unnecessary costs.

Request Quotes from Multiple Suppliers

Never settle for the first quote you receive:

• Use Online Quote Tools: Many custom apparel companies offer instant pricing calculators—use them to compare costs quickly.
• Ask About Hidden Fees: Inquire about setup fees, art fees, shipping, and rush charges. Some companies advertise low base prices but add significant extras.
• Negotiate: For large orders, don’t hesitate to ask for a discount or free setup fees—many suppliers are willing to negotiate.

Prepare Your Artwork in Advance

Well-prepared artwork speeds up production and avoids extra charges:

• Submit Print-Ready Files: Ensure your design is the correct size, resolution, and format (ideally 300 DPI or vector).
• Specify Pantone (PMS) Colors: If color accuracy is crucial, provide Pantone color codes to avoid miscommunication.
• Confirm Placement and Size: Clearly indicate where and how large the design should be printed to prevent back-and-forth revisions.

By planning ahead, simplifying your design, and leveraging bulk pricing, you can get high-quality custom t-shirts at the best possible price. Always communicate clearly with your supplier and compare multiple options to ensure you’re getting the best value for your budget.