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

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

When applying custom iron-on designs to T-shirts, the fabric composition plays a crucial role in the final result—impacting adhesion, durability, softness, and appearance. Choosing the right shirt material ensures your design looks professional and lasts through washes. Here’s a breakdown of the three most common fabric types: 100% cotton, 50/50 blends, and tri-blends.

100% Cotton

Pros:
– Excellent Heat Resistance: Cotton can withstand high temperatures, making it ideal for heat pressing. This ensures strong adhesion of iron-on vinyl or transfers.
– Superior Adhesion: Provides a stable, flat surface for iron-ons, resulting in crisp, long-lasting designs.
– Absorbent and Breathable: Offers comfort and a classic T-shirt feel, ideal for everyday wear.

Cons:
– Prone to Shrinkage: May shrink significantly (up to 5–10%) after washing, especially if not pre-shrunk.
– Less Durable Over Time: More susceptible to pilling and wear with repeated washing.
– Can Wrinkle Easily: Requires more careful ironing and storage.

Best For: Traditional, heavyweight T-shirts where durability and professional results are top priorities. Ideal for bold, detailed designs using HTV (Heat Transfer Vinyl).

50/50 Cotton-Polyester Blend

Pros:
– Reduced Shrinkage: Blending cotton with polyester helps minimize shrinkage during washing.
– Increased Durability: Polyester adds strength, helping the shirt maintain shape and resist pilling.
– Good Heat Tolerance: Withstands standard heat press temperatures well, though care should be taken not to overheat (polyester can scorch above 320°F).
– Balanced Feel: Offers a soft hand feel with improved resilience.

Cons:
– Slightly Lower Adhesion: Polyester content can reduce the surface area available for vinyl bonding, potentially leading to less durability than on 100% cotton.
– Risk of Scorching: Requires lower pressing temperatures and shorter durations to avoid melting or shiny marks on polyester fibers.

Best For: Budget-friendly, everyday wear shirts. Great for casual designs and environments where shrinkage is a concern. Use medium heat (around 270–290°F) and a protective parchment sheet.

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

Pros:
– Ultra-Soft Feel: Known for its luxurious, lightweight, and slightly drapey texture—popular in fashion-forward tees.
– Minimal Shrinkage: Very stable after washing due to high synthetic content.
– Great Drape and Aesthetic: Offers a vintage, lived-in look that appeals to many consumers.

Cons:
– Heat Sensitivity: Rayon and polyester are prone to melting or scorching at high temperatures. Requires careful, low-heat application.
– Reduced Adhesion: The smooth, soft surface can make it harder for vinyl to bond securely, especially on high-movement areas.
– Faster Wear on Design: The fabric’s softness can lead to faster cracking or peeling of vinyl with repeated use and washing.

Best For: Fashion tees, lightweight garments, and designs where comfort and drape are more important than extreme durability. Use low heat (around 265–275°F), shorter press times, and consider softer vinyl types like stretch or flocked HTV.

Final Tips for Success

• Always Pre-Press: Remove moisture and wrinkles before applying the design.
• Use a Protective Layer: Place a Teflon sheet or parchment paper over the design to prevent scorching, especially on blends.
• Follow Vinyl Manufacturer Guidelines: Adjust time, temperature, and pressure based on both the fabric and the vinyl type.
• Test First: Do a sample application on a scrap or inconspicuous area to fine-tune settings.

By matching your iron-on method to the fabric type, you’ll achieve professional, durable results every time.

How to Get the Best Price on Custom T-Shirt Iron-Ons (Bulk & Artwork Tips)

Getting custom iron-ons for t-shirts in bulk can be a cost-effective way to create branded apparel, team uniforms, or event merchandise. To maximize your savings and ensure top-quality results, focus on smart ordering strategies and proper artwork preparation.

Leverage Bulk Quantity Breaks

The most effective way to lower the unit cost of custom iron-ons is by ordering in larger quantities. Most suppliers offer tiered pricing, meaning the price per piece decreases as your order size increases.

• Understand Tiered Pricing: Suppliers typically set quantity brackets (e.g., 50–99, 100–249, 250–499, 500+). Jumping to the next tier often results in significant per-unit savings. For example, ordering 250 instead of 99 might cut the cost per iron-on by 30–50%.
• Plan for Future Needs: If you anticipate needing more iron-ons later, consider ordering a larger batch now to lock in lower pricing. Most iron-ons have a long shelf life when stored properly.
• Combine Orders: If you’re part of a group, team, or organization, combine orders to reach higher quantity tiers and share the savings.
• Negotiate with Suppliers: For very large orders (500+ units), don’t hesitate to ask for a custom quote. Many suppliers are willing to offer additional discounts for bulk commitments.

Optimize Artwork for Cost and Quality

High-quality artwork not only ensures a professional final product but also helps avoid costly reprints or delays. Follow these tips to streamline production and reduce costs.

• Use Vector Files (AI, EPS, SVG): Vector graphics scale infinitely without losing quality and are preferred by most print shops. They ensure crisp edges and precise colors, minimizing errors during production.
• Provide High-Resolution Raster Files (300 DPI): If using PNG or JPEG, ensure your design is at least 300 DPI at the final print size. Low-resolution images may require redrawing or upscaling, adding to costs.
• Simplify Your Design: Fewer colors and simpler designs often reduce production complexity and cost. Some suppliers charge extra for designs with many color layers or intricate details.
• Follow Color Guidelines: Use Pantone (PMS) colors if color accuracy is critical, or confirm with your supplier which color mode (CMYK or RGB) they prefer. Unnecessary color corrections can lead to added fees.
• Include Proper Bleed and Safe Zones: Add a 1/8-inch bleed around your design and keep critical text and elements within a safe margin to avoid trimming issues.
• Submit Print-Ready Files: Double-check that your file includes all fonts (or is outlined), is in the correct color mode, and matches the requested dimensions. This reduces back-and-forth and potential rush fees.

By strategically using bulk quantity breaks and submitting optimized artwork, you can significantly reduce your cost per iron-on while ensuring a high-quality, professional result. Always request a digital proof before production to confirm design accuracy and avoid costly mistakes.