Comparison of Screen Printing, DTG, and Heat Transfer for Custom T-Shirt Design

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

When designing custom t-shirts, the fabric you choose plays a crucial role in comfort, durability, print quality, and overall customer satisfaction. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends will help you make the best choice for your project. Here’s a breakdown of each option:

100% Cotton

Pros:
– Soft and Breathable: Ideal for warm weather and everyday wear, cotton feels natural against the skin.
– Great for Printing: Holds vibrant screen prints and direct-to-garment (DTG) inks exceptionally well.
– Eco-Friendly Option: Biodegradable and often available in organic varieties (e.g., organic cotton).
– Classic Feel: Offers a traditional, slightly heavier t-shirt experience that many people prefer.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster with repeated washing and develop pilling.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: Holds sweat and takes longer to dry.

Best For: Casual wear, events, screen-printed promotional shirts, or when a classic, natural fabric feel is desired.

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

Pros:
– Durability: Polyester adds strength, making the fabric more resistant to shrinking, fading, and wear.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Moisture Wicking: Polyester helps draw moisture away from the skin, drying faster than cotton.
– Affordable: Often priced lower than tri-blends, offering a budget-friendly alternative.

Cons:
– Less Breathable: Not as airy as 100% cotton, which may feel warmer in hot climates.
– Slight Sheen: Can have a shinier appearance, which may not suit all design styles.
– Printing Considerations: May require pretreatment for DTG printing to prevent ink bleed.

Best For: Workwear, active environments, budget-conscious bulk orders, and promotional items that need to withstand frequent washing.

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

Pros:
– Ultra-Soft Feel: Often described as having a “buttery” or vintage texture due to the rayon content.
– Excellent Drape: Flatters the body with a relaxed, slightly fitted silhouette.
– Color Retention: Vibrant prints with a vintage, lived-in look—ideal for fashion-forward designs.
– Lightweight and Drapes Well: Great for trendy, form-fitting styles.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Less Durable: Rayon can weaken when wet and may not withstand heavy use or frequent washing as well.
– Shrinking Risk: More prone to shrinking if not washed properly (cold water recommended).
– Special Care Needed: Often requires gentle washing and air drying.

Best For: Fashion tees, boutique brands, premium gift items, and designs that benefit from a soft, vintage aesthetic.

Final Tips for Choosing

• Consider the Use Case: Is the shirt for daily wear, events, work, or fashion?
• Think About Climate: Cotton breathes well in heat; blends offer better moisture management.
• Evaluate Print Needs: High-detail designs may benefit from tri-blend’s smooth surface, while bold logos shine on cotton.
• Budget Matters: Tri-blends are premium; 50/50 blends offer a middle ground.

By matching your fabric choice to your design goals and audience, you can create custom t-shirts that look great, feel comfortable, and stand the test of time.

How to Get the Best Price for Custom T-Shirt Design (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 getting the best price requires smart planning. By leveraging quantity discounts and optimizing your design process, you can significantly reduce costs without sacrificing quality. Here’s how:

Understand Bulk Quantity Breaks

Most screen printing and embroidery services offer tiered pricing based on order volume. The more shirts you order, the lower the cost per unit.

• Know the thresholds: Common quantity breaks are 12, 24, 50, 100, 250, and 500 units. For example, pricing might drop at 50 shirts and again at 100.
• Order at the break point: It’s often cheaper per shirt to order 100 instead of 75. Evaluate whether the extra shirts are worth the savings.
• Consolidate designs: Fewer unique designs mean lower setup fees. If possible, use one design across multiple shirt colors or sizes.

Choose the Right T-Shirt Style and Brand

Not all blanks are created equal—and pricing varies widely.

• Stick to budget-friendly blanks: Basic 100% cotton or cotton-polyester blends (like Gildan, Hanes, or Bella+Canvas 3001) offer great value.
• Avoid premium fabrics for bulk orders: Organic cotton or performance blends cost more. Reserve them for small, high-end runs.
• Negotiate with suppliers: If ordering 250+ units, ask for a custom quote—many printers offer additional discounts for large volume.

Optimize Your Artwork for Cost Efficiency

The design can dramatically affect printing costs—especially with screen printing.

• Limit the number of colors: Each ink color requires a separate screen and setup. Designs with 1–3 colors are the most affordable.
• Use vector files (AI, EPS, PDF): These scale cleanly and are preferred by printers. Avoid low-res JPEGs or PNGs.
• Simplify your design: Avoid tiny text or fine details that may not print well. Bold, clean graphics save time and money.
• One design per location: Printing on just the front or back is cheaper than both. Avoid multiple print locations unless necessary.

Get Multiple Quotes

Don’t settle for the first quote.

• Compare 3–5 reputable suppliers: Look at online printers (like Custom Ink, Printful, or Printify) and local screen shops.
• Check for hidden fees: Some include setup, shipping, or tax in the final price. Ask for an all-in quote.
• Look for promo codes and seasonal deals: Many companies offer discounts for first-time buyers or during back-to-school/holiday seasons.

Plan Ahead and Order Early

Rushing an order often leads to higher costs.

• Avoid rush fees: Standard production times are 7–14 days. Expedited service can add 25–50% to your bill.
• Forecast demand accurately: Over-ordering wastes money, under-ordering misses out on quantity breaks. Consider past events or sales data.
• Store extra shirts: High-quality blanks last years if stored properly. Buying in bulk now can save money on future needs.

Final Tips for Maximum Savings

• Bundle with other products: Some suppliers offer discounts when ordering hats, hoodies, or tote bags with shirts.
• Ask about reorders: Many printers keep your design on file and offer discounted re-runs without setup fees.
• Request a physical sample: Before mass production, order a sample to ensure color, fit, and print quality meet expectations.

By combining smart bulk ordering, efficient design choices, and strategic supplier selection, you can achieve professional-quality custom t-shirts at the best possible price.