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

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

When personalizing your look or branding with custom embroidered t-shirts, the fabric you choose plays a crucial role in both the final appearance and the longevity of your design. Understanding the differences between common t-shirt materials—100% cotton, 50/50 cotton-polyester blends, and tri-blends—can help you make the best choice for your project. Here’s what you need to know.

100% Cotton: Classic Comfort with Considerations

100% cotton t-shirts are beloved for their soft hand feel, natural breathability, and timeless appeal. They drape well and are ideal for casual, everyday wear.

Pros for Embroidery:
– Soft, natural texture that feels comfortable against the skin.
– Excellent color absorption, allowing for vibrant thread colors.
– Ideal for traditional, vintage, or organic branding aesthetics.

Cons for Embroidery:
– Prone to shrinking, especially if not pre-shrunk.
– Can wrinkle and lose shape over time.
– Softer knit may require stabilizers during embroidery to prevent puckering.
– Less durable than blended fabrics; may wear thin with heavy use or frequent washing.

Best For: Casual wear, eco-conscious brands, vintage styles, and embroidery with moderate stitch counts.

50/50 Cotton-Polyester Blend: The Balanced Performer

A 50/50 blend combines the comfort of cotton with the durability and resilience of polyester. This hybrid fabric is a popular choice for promotional and workwear apparel.

Pros for Embroidery:
– Resists shrinking and fading better than 100% cotton.
– Holds its shape well, minimizing distortion of the embroidered design.
– Slightly stiffer fabric provides a stable base for intricate embroidery.
– More affordable and durable than pure cotton.

Cons for Embroidery:
– Can feel less breathable and slightly synthetic.
– May require heat transfer during embroidery to prevent sheen differences (polyester can reflect light differently than cotton).
– Risk of scorching if embroidery machine heat settings are too high.

Best For: Corporate uniforms, promotional items, sportswear, and high-wear environments where durability matters.

Tri-Blends: Softness and Style with a Modern Edge

Tri-blend t-shirts typically mix cotton, polyester, and rayon (or sometimes modal). The result is a lightweight, ultra-soft fabric with a slightly heathered appearance and excellent drape.

Pros for Embroidery:
– Exceptionally soft and smooth texture, resembling a vintage or luxury feel.
– Minimal shrinkage and great shape retention.
– Attractive drape ideal for fashion-forward or fitted styles.

Cons for Embroidery:
– More delicate fabric—can be prone to snagging or shifting during stitching.
– Requires careful hooping and stabilizer use to avoid distortion.
– Rayon content may increase the risk of thread runs or fabric tears if not handled properly.
– Generally more expensive than cotton or 50/50 blends.

Best For: Fashion apparel, boutique brands, and lightweight designs with minimal to moderate embroidery detail.

Final Tips for Choosing the Right Fabric

• Consider the End Use: Will the shirt be worn daily, in a work environment, or as a fashion statement?
• Design Complexity: Heavier, denser embroidery works better on sturdier fabrics like 50/50 blends. Delicate designs can suit tri-blends or cotton.
• Care Instructions: Always wash embroidered garments inside out and on a gentle cycle, especially with tri-blends and 100% cotton.
• Test First: Request a sample stitch-out on your chosen fabric to assess how the design will look and feel.

By matching your embroidery goals with the right fabric, you’ll ensure your custom t-shirts look great, wear well, and reflect your intended style.

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

Understand Bulk Quantity Breaks

One of the most effective ways to reduce the cost per unit for custom t-shirt embroidery is by ordering in bulk. Most embroidery suppliers offer tiered pricing based on quantity, meaning the more units you order, the lower the price per shirt.

• Know the Break Points: Common quantity tiers include 12, 24, 36, 72, 144, and 288 units. Prices typically drop significantly at these thresholds. For example, ordering 144 shirts may be much cheaper per unit than ordering 100.
• Plan Ahead: If you anticipate needing more shirts in the future, consider ordering a larger quantity now to take advantage of lower rates.
• Combine Orders: If you’re part of a team, organization, or business, coordinate with others to pool orders and reach higher quantity tiers.

Choose the Right Garments

The type of t-shirt you select impacts both quality and cost. To maximize value:

• Stick to Standard Styles: Basic, widely available blanks (like Gildan, Hanes, or Bella+Canvas) are usually cheaper and offer better bulk pricing.
• Avoid Premium Fabrics for Bulk Orders: While softshell or performance fabrics look great, they dramatically increase costs. Reserve these for small, high-impact orders.
• Buy in Bulk: Some suppliers offer discounts if you purchase blank shirts in bulk separately—just ensure your embroidery provider allows customer-supplied garments.

Optimize Your Embroidery Design

The complexity of your design directly affects pricing. Simplifying your artwork can lead to big savings.

• Limit Stitch Count: Embroidery is priced partly by stitch count. High stitch counts increase time, thread use, and wear on machines. Aim for under 5,000–7,000 stitches for standard chest logos.
• Simplify Details: Avoid fine lines, small text, and gradients. Convert intricate designs into clean, bold versions suitable for stitching.
• Reduce Thread Changes: Each time the machine switches thread colors, it adds setup time. Limit your design to 5–6 colors or fewer to keep costs down.

Prepare Artwork Properly

Submitting artwork in the correct format saves time and avoids extra fees.

• Provide Vector Files: Supply your logo in vector formats like .AI, .EPS, or .SVG. These allow clean scaling and easy digitization.
• Avoid Low-Resolution Images: Raster images (like JPEGs or PNGs) with low DPI require costly redrawing or digitizing.
• Confirm Digitization Fees: Many companies charge a one-time setup fee to convert your artwork into an embroidery file. Ask if this fee is waived for larger orders or if it’s reusable for future reorders.

Get Multiple Quotes

Pricing varies widely between providers. Always shop around:

• Compare Stitch-Based vs. Flat-Rate Pricing: Some charge per 1,000 stitches; others offer flat rates per location (e.g., left chest). Calculate which is better for your design.
• Ask About Hidden Fees: Inquire about setup, digitization, hooping, and rush charges. These can add up quickly.
• Consider Local vs. Online Vendors: Local shops may offer faster turnaround and easier communication, while online suppliers often have lower overhead and better bulk rates.

Place Orders Strategically

Timing and order structure can impact pricing:

• Avoid Rush Orders: Expedited processing often comes with a 25–50% markup. Plan ahead to qualify for standard production times.
• Order All at Once: Splitting a 200-unit order into two 100-unit batches means missing out on volume discounts.
• Reuse Embroidery Files: If you reorder the same design, confirm that digitized files are saved and reusable to avoid paying setup fees again.

Build a Relationship with Your Supplier

Long-term partnerships can lead to better pricing and service:

• Negotiate Contracts: For recurring orders (e.g., annual uniforms), negotiate a standing rate or discount schedule.
• Provide Consistent Demand: Suppliers may offer loyalty discounts or early access to promotions if you’re a repeat customer.

By leveraging bulk pricing, optimizing your design, and working smartly with suppliers, you can achieve high-quality custom t-shirt embroidery at a fraction of the cost.