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 with few colors | Small orders, detailed/full-color designs | Small batches, quick turnaround, on-demand |
| Setup Time & Cost | High setup time and cost due to screens | Minimal setup; low prep cost | Low setup; design prep required |
| Print Quality | Vibrant, durable, consistent on dark garments | High detail, photo-realistic; best on light fabrics | Good detail; may feel plasticky or crack over time |
| Color Accuracy | Excellent with spot colors | Very good; RGB to CMYK conversion needed | Good; depends on printer and transfer type |
| Fabric Compatibility | Works on cotton, polyester, blends (with adjustments) | Best on 100% cotton; limited on polyester | Works on cotton, polyester, blends |
| Durability | Very durable; withstands many washes | Good; may fade after repeated washes | Varies; can crack, peel, or fade over time |
| Cost per Unit | Low for large quantities | Higher per unit; cost-effective for small runs | Moderate; higher for large volumes |
| Minimum Order Quantity | Typically high (e.g., 25+ per design) | No minimum; ideal for 1-off prints | No minimum; great for single items |
| Production Speed | Fast once set up; slow for small orders | Slower per unit; good for small batches | Fast for small runs; manual pressing needed |
| Design Flexibility | Limited by number of colors and screens | Unlimited colors; no design complexity limits | Full-color designs; limited by transfer size |
| Eco-Friendliness | Uses plastisol (less eco-friendly) or water-based inks | Uses water-based inks; more eco-friendly | Varies; some transfers involve plastics |
| Ideal Use Cases | Bulk merch, logos, events, sports teams | Art prints, photos, custom one-offs | Retail samples, prototypes, short runs |

This table helps identify the best printing method based on order size, design complexity, budget, and durability needs.

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

Selecting the right fabric is crucial when designing custom t-shirts. The material impacts comfort, durability, appearance, and how well your design prints. Here’s a breakdown of the three most popular options: 100% cotton, tri-blends, and polyester.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, comfortable feel ideal for everyday wear, especially in warm weather.
– Eco-Friendly Option: Biodegradable and often available in organic forms.
– Great for Printing: Holds screen printing and direct-to-garment (DTG) ink well, producing vibrant, crisp designs.
– Classic Look and Feel: Provides a traditional t-shirt aesthetic that appeals to a broad audience.

Cons:
– Prone to Shrinkage: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster, fade, or pill over time with frequent washing.
– Wrinkles Easily: Tends to wrinkle more than synthetic blends.

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

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

Pros:
– Super Soft and Draped: Offers a luxuriously soft hand-feel with a slight stretch and elegant drape.
– Reduced Shrinkage: More stable than 100% cotton, especially after washing.
– Color-Rich Prints: The polyester content enhances color vibrancy and allows for soft, vintage-style prints.
– Wrinkle-Resistant: Holds its shape well and resists creasing.

Cons:
– Less Breathable: Not as airy as pure cotton, which may be less comfortable in hot climates.
– Can Pill Over Time: May develop small fabric balls with repeated wear and washing.
– Higher Cost: Typically more expensive than 100% cotton or polyester options.

Best For: Fashion-forward apparel, premium custom tees, vintage-inspired designs, and gift items.

Polyester

Pros:
– Highly Durable: Resistant to shrinking, stretching, and wrinkles.
– Moisture-Wicking: Ideal for athletic wear and activewear due to its ability to draw sweat away from the skin.
– Quick-Drying: Dries faster than cotton or tri-blend fabrics.
– Colorfast: Retains print colors well, especially with dye-sublimation printing.

Cons:
– Less Breathable: Can feel clammy or hot in warm environments.
– Static and Pilling: May attract lint or develop static electricity.
– Less Softness: Often has a slicker, less natural feel compared to cotton or tri-blend.

Best For: Performance wear, sportswear, outdoor events, all-over prints (using dye-sublimation), and high-durability needs.

Choosing the Right Fabric for Your Custom T-Shirt

• Choose 100% Cotton if you want a classic, breathable, and eco-friendly option perfect for casual, everyday tees.
• Opt for Tri-Blend when you want a premium, soft, and stylish look with enhanced print quality and comfort.
• Go with Polyester for performance-driven garments, vibrant all-over prints, or situations requiring durability and moisture management.

Understanding these fabric types helps ensure your custom t-shirt not only looks great but also meets the needs of your intended audience and use case.

How to Get the Best Price for Custom T-Shirt Design

Getting high-quality custom t-shirts at the best price—especially for bulk orders—requires smart planning, strategic vendor selection, and efficient artwork preparation. Whether you’re ordering for a business, event, or promotional campaign, these tips will help you maximize savings without sacrificing quality.

Leverage Bulk Discounts Effectively

One of the most effective ways to reduce the per-unit cost of custom t-shirts is by taking advantage of bulk pricing. Here’s how to do it smartly:

• Order in Larger Quantities: Most printers offer tiered pricing—typically the more you order, the lower the price per shirt. For example, ordering 100 shirts might cost $10 each, while 500 shirts could drop to $6 each. Assess your needs carefully to balance budget and demand.

• Consolidate Sizes and Colors: Stick to a single shirt color and limit size variations (S, M, L, XL) to reduce setup and sorting costs. Mixing too many colors or styles can increase printing complexity and price.

• Choose Basic, High-Quality Blank Tees: Opt for standard, widely available blank t-shirts (like Gildan, Bella+Canvas, or Hanes). Premium or specialty fabrics (organic cotton, tri-blends) cost more, so reserve them only if necessary.

• Compare Multiple Suppliers: Get quotes from at least 3–5 reputable screen printers or online custom apparel platforms (like Custom Ink, Printful, or local screen printers). Be sure to compare not just price, but also turnaround time, shipping fees, and minimum order requirements.

• Ask About Promo Codes and Seasonal Deals: Many online vendors offer first-time discounts, referral bonuses, or seasonal sales. Sign up for newsletters or follow companies on social media to stay updated on deals.

Prepare Artwork to Minimize Costs and Delays

High-quality, properly formatted artwork can save you money by reducing reprints, setup fees, and production errors. Follow these artwork preparation tips:

• Use Vector Files (SVG, AI, EPS): Vector graphics scale infinitely without losing quality, making them ideal for printing. If you don’t have vector artwork, hire a designer to convert your logo or image into one.

• Keep Designs Simple: Fewer colors and simpler graphics reduce screen setup fees in screen printing. For example, a one-color design is significantly cheaper than a four-color process. Consider reducing color counts where possible.

• Follow Printer Specifications: Always check your printer’s guidelines for file resolution (300 DPI minimum), color mode (CMYK for printing), and file dimensions. Submitting incorrect formats may result in extra fees or delays.

• Avoid Full-Color or Photographic Prints Unless Necessary: Full-color designs often require more expensive printing methods like direct-to-garment (DTG). For large runs, stick to screen printing with limited colors to save costs.

• Get a Digital Proof First: Most printers offer free digital proofs. Review them carefully for color accuracy, placement, and sizing before approving production.

By combining smart bulk ordering strategies with professional artwork preparation, you’ll not only get the best price on custom t-shirts but also ensure a smooth, high-quality printing process.