Comparison: Screen Printing, DTG, and Heat Transfer for Custom T-Shirt Logos

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

When designing custom t-shirts with logos, the fabric you choose plays a crucial role in both the look and feel of the final product—and how well your logo stands out. Three of the most popular fabric options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Each has unique characteristics that affect durability, comfort, print quality, and care. Here’s what you need to know to make the best choice for your custom logo tees.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and breathable: Ideal for everyday wear, especially in warm climates.
– Excellent print surface: Absorbs ink well, making it perfect for vibrant screen printing and detailed logos.
– Natural and biodegradable: A more sustainable choice for eco-conscious brands.
– Gets softer with each wash: Improves in comfort over time.

Cons:
– Prone to shrinking: Especially if not pre-shrunk or washed in hot water.
– Less durable: Can wear out faster with frequent washing and heavy use.
– Wrinkles easily: Requires ironing or steaming for a crisp look.
– Holds moisture: Less ideal for athletic or performance wear.

Best For: Casual wear, vintage-style designs, eco-friendly brands, and logos with bold, traditional prints.

50/50 Blend: The Balanced Performer

Pros:
– Durable and long-lasting: Resists shrinking and fading better than 100% cotton.
– Wrinkle-resistant: Holds its shape and requires less ironing.
– Affordable: Often priced between cotton and tri-blends.
– Good printability: Works well with most printing methods, including DTG and screen printing.

Cons:
– Slightly less soft: Can feel a bit stiffer than 100% cotton or tri-blends.
– Less breathable: The polyester content reduces airflow compared to pure cotton.
– May pill over time: Especially with frequent washing and friction.

Best For: Promotional events, workwear, budget-friendly giveaways, and environments where durability matters.

Tri-blends: Softness Meets Style

Pros:
– Ultra-soft and lightweight: Typically made from a mix of cotton, polyester, and rayon (e.g., 50/25/25), offering a smooth, vintage-like drape.
– Excellent drape and comfort: Flatters the body and feels luxurious.
– Reduced shrinkage: More stable than 100% cotton.
– Great for vintage or lifestyle branding: Ideal for fashion-forward or boutique-style logos.

Cons:
– More expensive: Higher cost due to premium materials and construction.
– Less durable: Can be more delicate, especially with repeated washing.
– Printing challenges: Rayon content may affect ink absorption; requires precise printing techniques.
– Not ideal for heavy use: Better suited for fashion wear than rugged environments.

Best For: High-end branding, boutique apparel, lifestyle brands, and soft, vintage-inspired logo designs.

Final Tips for Choosing the Right Fabric

• Consider your audience: Are they looking for comfort (cotton), durability (50/50), or style (tri-blend)?
• Think about the logo design: Intricate or colorful logos may perform best on 100% cotton or tri-blends, while simple designs work on all three.
• Factor in usage: Will the shirts be worn daily, used for sports, or given as event swag?
• Test samples: Order fabric swatches or sample shirts to feel the texture and test print quality before bulk ordering.

By understanding the strengths and limitations of 100% cotton, 50/50 blends, and tri-blends, you can select the ideal fabric that makes your custom t-shirt logo look great and feel even better.

How to Get the Best Price for Custom T-Shirt Logos (Bulk Quantity Breaks & Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, team, or event — but only if you know how to maximize savings. By leveraging quantity breaks and optimizing your artwork, you can significantly reduce your per-unit cost without sacrificing quality.

Understand Bulk Quantity Breaks

Screen printing and embroidery companies use tiered pricing based on order volume, known as “quantity breaks.” The more shirts you order, the lower the price per shirt.

• Typical Quantity Tiers:
• 12–24 units
• 25–49 units
• 50–71 units
• 72–95 units
• 96–144 units

• 145+ units

• Strategy: Always order at the top of a tier. For example, ordering 71 shirts costs more per unit than ordering 72, which qualifies for the next pricing tier.

• Tip: If you’re unsure about exact numbers, round up slightly to hit a lower price break. The small increase in total cost often saves significantly per shirt.

Choose the Right Printing Method

The printing technique impacts both price and quality. Select the method that matches your design complexity and budget.

• Screen Printing: Best for large, simple designs with few colors. Cost-effective for bulk orders (50+ shirts). Setup fees apply, but cost per shirt drops sharply with volume.
• DTG (Direct-to-Garment): Ideal for detailed, full-color designs. No setup fees, but higher per-shirt cost. Better for smaller runs or complex artwork.
• Embroidery: Great for logos on polos or hats. More expensive, but durable and professional. Pricing is based on stitch count.

Simplify Your Design to Reduce Costs

Complexity directly affects pricing, especially with screen printing.

• Limit Colors: Each color requires a separate screen and setup. Stick to 1–3 colors for maximum savings.
• Avoid Gradients and Fine Details: These may require DTG or additional screens, increasing cost. Opt for solid fills and bold lines.
• Use Vector Art: Ensure your logo is in vector format (AI, EPS, SVG) for clean scaling and easier reproduction.

Provide Print-Ready Artwork

Suppliers often charge for artwork setup or corrections. Save money by submitting professional-quality files.

• File Format: Deliver vector files (AI, EPS, SVG) whenever possible. For raster, use high-resolution PNG or TIFF (300 DPI at actual print size).
• Color Mode: Use CMYK or specified spot colors (Pantone) for accurate color matching.
• Outline Text: Convert all text to outlines in vector files to prevent font issues.
• Clear Background: Ensure your logo has a transparent or solid background as required.

Compare Multiple Vendors

Pricing varies widely between suppliers. Don’t settle for the first quote.

• Get at least 3 quotes from reputable screen printers or online platforms (e.g., Printful, Custom Ink, local shops).
• Ask about hidden fees: Setup, screen cleaning, color changes, and shipping can add up. Ensure quotes are all-inclusive.
• Check reviews and samples: Quality matters. Request physical samples to assess fabric and print durability.

Choose Affordable, High-Quality Apparel

The shirt itself impacts cost. Balance price and quality.

• Budget-Friendly Blends: 100% cotton or cotton-poly blends (e.g., Gildan, Hanes) offer good value.
• Avoid Premium Brands Unless Necessary: Designer blanks (e.g., Bella+Canvas, Next Level) cost more — only use if branding demands it.
• Stick to One Style: Ordering multiple styles increases setup and fulfillment costs.

Plan Ahead and Avoid Rush Fees

Rush orders can double or triple production costs.

• Place Orders Early: Allow 2–3 weeks for production and shipping.
• Schedule for Off-Peak Times: Avoid holidays and back-to-school seasons when demand (and prices) spike.

Bundle Orders and Reorder Smartly

• Combine Needs: If multiple teams or departments need shirts, consolidate into one large order.
• Reorder at Same Time: If you’ll need more later, order extra now to reuse screens and hit higher quantity breaks.

By understanding quantity breaks, simplifying designs, and preparing professional artwork, you’ll get the best price on your custom t-shirt logos — without compromising on quality.