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

100% Cotton vs. 50/50 Blend vs. Tri-blends: Choosing the Best Fabric for Your Custom Long Sleeve T-Shirt

When designing custom long sleeve T-shirts, selecting the right fabric is crucial. It affects comfort, durability, print quality, and overall wearability. Three popular options dominate the market: 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s a detailed comparison to help you choose the best fabric for your needs.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and Breathable: Offers excellent breathability, making it ideal for everyday wear and mild climates.
– Natural Fiber: Hypoallergenic and gentle on sensitive skin.
– Eco-Friendly: Biodegradable and often available in organic options.
– Great for Printing: Holds screen prints, direct-to-garment (DTG), and heat transfers well, especially on lighter colors.

Cons:
– Prone to Shrinking: Can shrink if not pre-shrunk or washed improperly.
– Less Durable: More susceptible to pilling and wear over time, especially with frequent washing.
– Wrinkles Easily: Tends to wrinkle and lose shape faster than synthetic blends.
– Absorbs Moisture: While breathable, it retains sweat and dries slowly—less ideal for active use.

Best For: Casual wear, eco-conscious brands, vintage-style prints, and customers prioritizing softness and natural materials.

50/50 Blend: The Balanced Performer

Pros:
– Durability: Polyester adds strength, reducing shrinkage and pilling.
– Shape Retention: Holds its form better after repeated washes.
– Fade Resistance: Withstands fading better than 100% cotton, especially with vibrant prints.
– Affordable: Often more budget-friendly than tri-blends while offering enhanced performance.

Cons:
– Less Breathable: Polyester content can trap heat, making it less ideal for hot weather.
– Slight Sheen: May have a subtle synthetic look compared to 100% cotton.
– Static: Can generate static electricity in dry conditions.

Best For: Workwear, promotional shirts, schools, and events where durability and cost-efficiency matter. Great for bold, colorful designs that need to last.

Tri-Blends: Softness Meets Performance

Pros:
– Ultra-Soft Hand Feel: Typically made from a mix of cotton, polyester, and rayon, resulting in a buttery-soft, lightweight fabric.
– Excellent Drape: Flattering fit with a slightly vintage, relaxed look.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic fibers.
– Moisture-Wicking: Polyester and rayon help move moisture away from the skin.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends.
– Less Durable: Rayon can weaken when wet and may wear faster with heavy use.
– Special Care Needed: Requires gentle washing to maintain softness and prevent pilling.
– Printing Challenges: The smooth surface can make ink adhesion trickier; DTG often works best.

Best For: Premium custom apparel, fashion-forward brands, boutique stores, and customers seeking a luxury feel. Ideal for soft, vintage-inspired designs.

Final Tips for Choosing

• Consider the Use Case: Is it for daily wear, events, or active use?
• Think About Climate: Cotton breathes well in warm weather; blends offer versatility.
• Evaluate Print Needs: High-detail prints may benefit from tri-blend’s smooth surface, while bold graphics thrive on 50/50 blends.
• Budget Matters: 100% cotton and 50/50 blends are generally more affordable than tri-blends.

By weighing these factors, you can select the perfect fabric that aligns with your brand, audience, and design goals—ensuring your custom long sleeve T-shirts look great and feel even better.

How to Get the Best Price on Custom Long Sleeve T-Shirts (Bulk Orders & Artwork Tips)

Ordering custom long sleeve 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. Here’s how to secure the best possible price while ensuring high-quality results.

Understand Bulk Pricing and Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on order volume. The more you order, the lower the per-unit cost. Take advantage of this by:

• Ordering in larger quantities: Move up to the next pricing tier (e.g., 100 → 150 or 250 units) to reduce the cost per shirt.
• Consolidating orders: Combine multiple small needs (e.g., staff, events, merch) into one bulk order.
• Planning ahead: Forecast your needs for the year to place fewer, larger orders instead of multiple small ones.

Tip: Some suppliers offer discounted rates even at 50 units—ask about minimums and tier thresholds when getting quotes.

Choose the Right Blank Long Sleeve Shirt

The base garment significantly impacts your final cost. To save money:

• Select value-priced but quality brands: Brands like Gildan Heavy Cotton, Bella+Canvas 3719, or Hanes Beefy-T offer durability at lower price points.
• Stick to standard colors: White, black, navy, and heather gray are usually cheaper than specialty or neon colors.
• Avoid premium fabrics unless necessary: 100% cotton is often less expensive than cotton-blends or performance fabrics.

Optimize Your Artwork for Cost-Efficiency

The design complexity directly affects printing costs. Follow these tips to keep prices low:

• Limit the number of print colors: Each additional color increases setup and printing time. Stick to 1–3 colors when possible.
• Simplify your design: Avoid fine details or gradients that may require expensive printing methods like simulated process or DTG.
• Use vector artwork: Supply logos and graphics in vector format (AI, EPS, or PDF) to avoid extra file conversion fees.
• Minimize print locations: Printing on just the front or sleeve is cheaper than front and back.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote. Reach out to at least 3–5 reputable suppliers to compare pricing, turnaround time, and quality.

• Ask about package deals: Some providers offer discounts when combining long sleeve tees with other apparel.
• Negotiate based on volume: If you’re placing a large order or expect repeat business, ask for a custom discount.
• Check for seasonal promotions: Many printers offer discounts during off-peak times (e.g., early spring or late summer).

Consider Printing Method and Setup Fees

• Screen printing is cheapest for large runs (50+ units) with simple designs.
• DTG (Direct-to-Garment) may be cost-effective for small quantities or complex, full-color designs—but usually more expensive per unit in bulk.
• Request a waiver on setup fees: Some suppliers waive or reduce setup costs for large orders.

Final Tips for Maximum Savings

• Order sizes strategically: Use size breakdowns based on past data to avoid over-ordering unpopular sizes.
• Approve a physical sample first: Avoid costly reprints by verifying color, fit, and print quality upfront.
• Factor in shipping: Choose suppliers with flat-rate or free shipping on bulk orders to reduce total cost.

By combining smart bulk ordering, simplified artwork, and strategic supplier selection, you can get high-quality custom long sleeve t-shirts at the best possible price.