Comparison Table: Screen Printing, DTG, and Heat Transfer for Bulk Custom T-Shirts

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

When ordering custom t-shirts in bulk for your team, event, or brand, selecting the right fabric is crucial. It affects comfort, durability, appearance, and print quality. The three most popular options are 100% cotton, 50/50 blends, and tri-blends. Here’s a breakdown to help you decide which is best for your needs.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warm weather.
– Natural Fiber: Eco-friendly and biodegradable; ideal for those seeking sustainable options.
– Great for Printing: Holds screen prints and direct-to-garment (DTG) prints well, with vibrant results.
– Widely Available: Found in a range of weights (e.g., 5.0 oz, 6.1 oz) and styles.

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk.
– Less Durable: Can wear out faster with frequent washing and heavy use.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: Holds sweat, making it less ideal for active wear.

Best For: Casual wear, promotional events, retail apparel, or when a natural, soft hand-feel is a priority.

50/50 Blend: The Balanced Choice

Pros:
– Durability: The polyester adds strength, reducing pilling and extending the shirt’s life.
– Less Shrinkage: Resists shrinking better than 100% cotton.
– Affordable: Often priced lower than tri-blends.
– Good Print Surface: Works well with most printing techniques.

Cons:
– Slightly Less Soft: Can feel a bit rougher than 100% cotton or tri-blends.
– Less Breathable: Polyester content reduces airflow compared to pure cotton.
– May Pill Over Time: Especially with lower-quality blends.

Best For: Budget-conscious bulk orders, workwear, school events, or situations requiring long-lasting shirts.

Tri-Blends: Softness and Style Combined

Pros:
– Ultra-Soft Hand Feel: A blend of cotton, polyester, and rayon creates a buttery-soft texture.
– Excellent Drape: Flattering fit with a slightly vintage, relaxed look.
– Reduced Shrinkage: More stable than 100% cotton.
– Fade Resistance: Retains color well after repeated washes.

Cons:
– Higher Cost: Typically more expensive due to materials and manufacturing.
– Delicate Fabric: Less durable under heavy use or rough handling.
– Printing Challenges: Rayon can absorb ink differently; may require specialty inks or techniques.

Best For: Premium apparel, fashion-forward designs, boutique brands, or when comfort and aesthetics are top priorities.

Final Tips for Bulk Orders

• Consider Your Audience: Are they athletes, office workers, or concert-goers? Match fabric to activity.
• Evaluate Print Design: Complex, colorful designs may benefit from tri-blends, while bold logos work well on 50/50 or cotton.
• Factor in Budget: 50/50 blends often offer the best value for large quantities.
• Request Samples: Always order swatches to feel the fabric and test print quality before committing.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the right fabric for your bulk custom t-shirt order—ensuring comfort, durability, and style for your customers or team.

How to Get the Best Price for Custom T-Shirts in Bulk

Ordering custom t-shirts in bulk is a cost-effective way to promote your brand, event, or team. To maximize savings and ensure high-quality results, consider these strategies for leveraging quantity breaks and optimizing your artwork.

Understand Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on volume, known as quantity breaks. These are specific order thresholds that unlock lower per-unit prices.

• Typical Quantity Tiers: Common breaks include 25, 50, 100, 250, and 500+ units. For example, ordering 99 shirts may cost more per shirt than ordering 100.
• Strategic Ordering: Aim to meet or slightly exceed the next quantity break. If 100 shirts cost $8 each but 250 cost $5.50, it may be worth ordering extra to hit the discount threshold.
• Ask for Custom Quotes: Some suppliers offer special pricing for large or repeat orders. Always request a custom quote if ordering over 500 units.

Choose the Right T-Shirt Style and Brand

Basic, widely available blanks (like Gildan, Bella+Canvas, or Hanes) are usually cheaper than premium or specialty brands. Opt for mid-tier quality for the best balance of cost and comfort.

• Stick to One Style: Mixing shirt types increases setup and printing costs. Standardizing your order reduces complexity and pricing.
• Light Colors Save Money: White and light-colored shirts are generally less expensive than dark or specialty colors.

Minimize Print Complexity

Simpler designs cost less to produce and allow for faster turnaround.

• Limit Print Locations: One print location (e.g., front chest) is cheaper than multiple (front, back, sleeves).
• Reduce Ink Colors: Each additional ink color increases screen setup and labor costs. Stick to 1–3 colors if possible.
• Avoid Full-Color or Photographic Prints: These often require costly digital printing or simulated process printing. Use vector-based, spot-color designs instead.

Optimize Your Artwork for Cost Efficiency

High-quality, print-ready artwork prevents delays and extra charges.

• Use Vector Files: Provide artwork in vector formats (AI, EPS, SVG) for crisp scaling and easier color separation.
• Simplify the Design: Remove gradients, shadows, and fine details that complicate printing.
• Confirm Color Matching: Use Pantone (PMS) colors to ensure consistency and avoid costly color corrections.
• Submit Mockups: Share a digital mockup with your printer to confirm placement, sizing, and colors before production begins.

Time Your Order Strategically

• Avoid Rush Fees: Plan ahead and allow 2–3 weeks for production and shipping. Rush orders can double printing costs.
• Look for Seasonal Promotions: Some suppliers offer discounts during slower months (e.g., late winter or early fall).

Compare Multiple Vendors

Don’t settle for the first quote. Get estimates from at least 3–5 reputable bulk t-shirt printers.

• Check Reviews and Samples: Request printed samples to evaluate quality.
• Clarify All Costs: Ensure quotes include printing, setup fees, shipping, and taxes. Some vendors hide fees until checkout.
• Consider Local vs. Online: Local screen printers may offer lower shipping costs and easier collaboration, while online bulk suppliers (like Custom Ink, Printful, or Awkward Styles) often have competitive pricing and volume discounts.

By leveraging quantity breaks, simplifying your design, and preparing professional artwork, you can significantly reduce the per-unit cost of custom t-shirts—without sacrificing quality.