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

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

When designing custom t-shirts or hoodies, the fabric you choose plays a crucial role in comfort, durability, appearance, and print quality. Three of the most popular fabric options are 100% cotton, 50/50 blends, and tri-blends. Each has unique characteristics that make it better suited for different uses and preferences. Here’s a breakdown to help you decide which is right for your project.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft, breathable, and comfortable against the skin—ideal for everyday wear.
– Highly absorbent, making it great for warm climates or active use.
– Excellent for screen printing, especially with water-based inks, due to its natural fiber content.
– Biodegradable and eco-friendly (when sustainably sourced).

Cons:
– Prone to shrinking, especially if not pre-shrunk or washed improperly.
– Less durable over time—can pill, thin, or wear out faster with frequent washing.
– Wrinkles easily and may lose shape after repeated use.
– Heavier feel compared to blended fabrics.

Best For: Casual, vintage-style t-shirts, eco-conscious brands, or customers prioritizing natural materials and softness.

50/50 Blend: The Balanced Choice

A 50/50 blend typically combines 50% cotton and 50% polyester.

Pros:
– Resists shrinking and wrinkling better than 100% cotton.
– More durable and long-lasting due to polyester’s strength.
– Lightweight and breathable, with improved moisture-wicking properties.
– Holds vibrant prints well and withstands repeated washes.
– Often more affordable than 100% cotton or tri-blends.

Cons:
– Slightly less soft than 100% cotton (though modern versions are much improved).
– Less breathable than pure cotton, which may feel warmer.
– Can develop pilling over time, especially with lower-quality fabric.

Best For: High-volume orders, promotional apparel, school events, or situations where durability and cost-efficiency matter.

Tri-Blends: Ultimate Softness and Style

Tri-blend fabrics usually combine cotton, polyester, and rayon (e.g., 50% poly, 25% cotton, 25% rayon).

Pros:
– Exceptionally soft with a luxurious, vintage-inspired drape.
– Lightweight and breathable with excellent moisture-wicking.
– Minimal shrinkage and great shape retention.
– Creates a soft, lived-in look that’s popular for fashion-forward designs.
– Prints beautifully with a slightly heathered, retro aesthetic.

Cons:
– More expensive than cotton or 50/50 blends.
– Less durable than 100% cotton or 50/50 due to rayon’s delicate nature.
– Can be prone to snagging or pilling with rough wear.
– Not as eco-friendly, especially due to rayon production concerns (though sustainable options exist).

Best For: Premium custom apparel, boutique brands, fashion-focused designs, and customers seeking a high-end, soft hand feel.

How to Choose the Right Fabric

Consider these factors when making your decision:

• Intended Use: For daily wear or work uniforms? Choose durability (50/50). For fashion statements? Try tri-blend. For eco-friendliness? Lean toward 100% cotton.
• Climate: Hot and humid areas benefit from cotton’s breathability; active use may favor blends for moisture management.
• Print Design: Bold graphics hold well on 50/50 blends. Soft, vintage looks shine on tri-blends.
• Budget: 50/50 blends often offer the best value; tri-blends are premium-priced.
• Target Audience: Athletes may prefer performance; eco-conscious buyers may favor organic cotton.

Ultimately, the best fabric depends on your goals, audience, and design vision. Sampling different fabrics can help you feel the differences firsthand before placing a large order.

How to Get the Best Price on Custom T-Shirts and Hoodies in Bulk

Ordering custom t-shirts and hoodies in bulk can be a cost-effective way to brand your team, promote your business, or organize events. To maximize your savings and ensure quality, follow these key strategies focused on bulk pricing and artwork optimization.

Leverage Bulk Quantity Breaks

One of the most effective ways to reduce your per-unit cost is by taking full advantage of quantity breaks offered by manufacturers.

• Order Larger Quantities: Most suppliers offer tiered pricing—typically at 50, 100, 250, 500, or 1,000 units. The higher the quantity, the lower the price per item. For example, ordering 250 shirts may cost $8 per unit, while 500 could drop to $6.50.

• Consolidate Orders: Combine upcoming needs into one large order. If you anticipate needing shirts for multiple events or teams, plan ahead and order together to reach higher volume tiers.

• Mix Styles Strategically: Some vendors allow you to mix t-shirts and hoodies within the same order while still qualifying for bulk pricing—check with your supplier. This lets you get variety without losing savings.

• Negotiate with Suppliers: Don’t hesitate to ask for a quote based on your target quantity. Some companies offer custom quotes that may include additional discounts or free setup fees for large orders.

Optimize Your Artwork for Lower Costs

The design process can significantly impact your final price. Simplifying your artwork helps reduce production costs—especially with printing methods like screen printing.

• Limit the Number of Colors: Each additional ink color requires a separate screen and increases setup time and cost. Stick to 1–3 colors whenever possible. For example, a one-color print is far cheaper than a full-color design.

• Use Vector Art: Provide logos and designs in vector format (e.g., .AI, .EPS, or .SVG) to ensure crisp, scalable prints. Raster files (like .JPG or .PNG) may need redrawing, potentially incurring extra fees.

• Simplify the Design: Avoid intricate details or gradients, which can complicate printing and increase costs. Bold, clean graphics reproduce better and are cheaper to produce.

• Minimize Print Locations: Printing on multiple locations (front, back, sleeves) increases labor and materials. Choose one or two key areas to keep prices down.

• Approve a Physical Sample First: Order a sample print before the full run. This ensures colors and placement are correct and prevents costly reprints due to errors.

By strategically using bulk quantity breaks and streamlining your artwork, you can significantly reduce costs while still achieving professional, high-quality custom apparel. Always request quotes from multiple suppliers and compare not just price, but also fabric quality, print durability, and customer service.