Comparison of Custom T-Shirt Printing Methods

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

When designing custom t-shirts online, one of the most important decisions you’ll make is choosing the right fabric. The material affects not only how the shirt feels and wears but also how your design prints and ages over time. Here’s a breakdown of the three most popular fabric options to help you make the best choice for your project.

100% Cotton: Classic Comfort and Softness

Pros:
– Ultra-soft feel, especially after washing
– Highly breathable, ideal for warm weather and active wear
– Excellent ink absorption, making it a great choice for vibrant, detailed designs
– Natural and biodegradable, appealing to eco-conscious customers

Cons:
– Prone to shrinking, especially if not pre-shrunk or washed improperly
– Less durable over time—can wear out, thin, or pill with frequent use
– Holds wrinkles and odors more than synthetic blends

Best For: Casual wear, vintage-style tees, screen printing, and customers who prioritize softness and natural fabrics.

50/50 Cotton-Polyester Blend: The Best of Both Worlds

Pros:
– Balances softness and durability—more resilient than 100% cotton
– Resists shrinking and wrinkling, maintaining shape after washes
– Lightweight and affordable, making it a popular choice for promotional apparel
– Good print surface, especially for standard screen printing and DTG (Direct-to-Garment)

Cons:
– Slightly less breathable than pure cotton
– Can feel less soft initially, though this improves with wear
– Polyester may cause pilling over time with friction

Best For: Budget-friendly bulk orders, promotional shirts, athletic or workwear, and environments where durability matters.

Tri-Blend (Typically Cotton, Polyester, Rayon): Soft, Drapey, and Stylish

Pros:
– Incredibly soft and smooth, with a luxurious, vintage-like feel
– Excellent drape, giving shirts a more fitted, fashionable silhouette
– Resists shrinking and fading better than 100% cotton
– Ideal for trendy, fashion-forward styles and modern unisex fits

Cons:
– More expensive than cotton or 50/50 options
– Less durable under heavy use or frequent washing
– May require special care (e.g., cold wash, low tumble dry) to maintain softness
– Prints may appear slightly softer or muted due to fabric texture

Best For: Fashion tees, boutique apparel, women’s or fitted styles, and designs aiming for a premium, vintage aesthetic.

Making the Right Choice

Consider these factors when selecting your fabric:
– Intended use: Everyday wear, events, retail, or uniforms?
– Target audience: Are they fashion-conscious, budget-focused, or eco-aware?
– Design complexity: Detailed artwork often performs best on 100% cotton or tri-blends.
– Care instructions: Will the shirt be washed frequently? Choose durability if so.
– Budget: Tri-blends cost more; 50/50 blends offer great value.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the perfect fabric for your custom t-shirt design—ensuring comfort, quality, and lasting appeal.

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

Ordering custom t-shirts in bulk online can be a cost-effective way to promote your brand, event, or team—but only if you know how to maximize savings and quality. Here’s how to get the best price without sacrificing design integrity, leveraging bulk quantity breaks and smart artwork practices.

1. Order in Larger Quantities for Bulk Discounts

Most online printers offer tiered pricing based on order volume. The more you order, the lower the per-unit cost.

• Understand Quantity Breaks: Look for pricing tiers (e.g., 50, 100, 250, 500+ units). Jumping to the next tier often results in significant savings per shirt.
• Plan Ahead: If you anticipate future needs, ordering more now can reduce long-term costs.
• Split Sizes, Not Orders: Order all shirts in one bulk run, varying only sizes and colors. Splitting orders negates bulk pricing.

2. Choose the Right Shirt Style and Brand

Not all shirts cost the same. Base prices vary by fabric, brand, and cut.

• Opt for economy or value-grade cotton (e.g., Gildan 5000, Hanes Beefy-T) for the lowest cost.
• Avoid premium brands (like Bella+Canvas 3001) unless necessary—they cost more.
• Consider unisex fits, which are typically cheaper and more versatile.

3. Simplify Your Design to Reduce Printing Costs

Printing costs depend on design complexity.

• Limit Print Colors: Each additional color increases setup and printing fees. Stick to 1–3 colors.
• Choose One-Side Printing: Front-only designs cost less than full front-and-back prints.
• Opt for Standard Print Areas: Chest prints are cheaper than oversized back or sleeve prints.

4. Use Vector Artwork to Avoid Extra Fees

Suppliers often charge for artwork cleanup if your file isn’t print-ready.

• Submit Vector Files: Use .AI, .EPS, or .SVG formats for crisp, scalable graphics.
• High-Resolution Raster Files: If using .PNG or .JPG, ensure 300 DPI at actual print size.
• Avoid Low-Quality Images: Blurry or pixelated artwork may require costly redesigns.

5. Compare Multiple Print-on-Demand & Bulk Suppliers

Pricing and quality vary widely across vendors.

• Compare popular platforms like Custom Ink, Printful, RushOrderTees, and SanMar.
• Use instant online quotes to test different quantities and options.
• Check for free shipping, promo codes, or seasonal discounts.

6. Group Orders to Maximize Savings

Combine orders from teammates, departments, or event participants.

• A single 200-unit order is cheaper than two 100-unit orders.
• Use online tools to collect size and color preferences easily.

7. Request a Physical Sample First

Avoid costly mistakes by ordering a sample shirt with your design.

• Verify print quality, color accuracy, and fabric feel.
• Some vendors offer free blank samples or discounted test prints.

8. Time Your Order Strategically

• Avoid peak seasons (spring for events, back-to-school).
• Look for holiday sales, end-of-quarter deals, or new customer discounts.

Final Tips for Best Value

• Double-check your design mockup before approving.
• Negotiate with suppliers for large orders—they may offer custom quotes.
• Save your artwork for reorders; most vendors keep files on file.

By leveraging bulk pricing, optimizing your design, and choosing the right supplier, you can get high-quality custom t-shirts at the best possible price—perfect for branding, promotions, or group apparel.