Screen Printing vs. DTG vs. Heat Transfer: A Comparison for Custom T-Shirt Makers

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|—————————-|——————————————|——————————————|——————————————-|
| Best For | High-volume orders, simple designs | Low-volume, complex/full-color designs | Small runs, quick turnaround, DIY projects |
| Setup Time & Cost | High setup time and cost (per color) | Minimal setup; low initial cost | Low to moderate setup; depends on method |
| Print Quality | Vibrant, durable, excellent opacity | Photorealistic, soft feel, less opaque on darks | Varies; can feel plasticky or crack over time |
| Durability | Very durable; withstands many washes | Good on 100% cotton; may fade on blends | Moderate; prone to cracking/peeling |
| Fabric Compatibility | Works best on cotton; limited on blends | Best on 100% cotton; struggles with polyester | Works on most fabrics, including blends |
| Color Capability | Limited by number of screens (spot colors) | Unlimited colors; gradients and photo-quality | Full color possible; depends on print method |
| Cost Efficiency | Cost-effective for large quantities | More expensive per unit for large runs | Cost-effective for very small quantities |
| Production Speed | Fast once set up; ideal for bulk orders | Slower; print time per garment | Fast for small batches; manual application |
| Design Flexibility | Low; design changes require new screens | High; easy to change designs digitally | High; quick digital changes |
| Eco-Friendliness | Moderate; uses plastisol (less eco) or water-based inks | High; water-based inks, less waste | Low to moderate; involves transfer paper/vinyl waste |
| Common Use Cases | Band tees, promotional shirts, sports uniforms | Artistic designs, photos, small batches | Personalized shirts, names/numbers, events |

Choose Screen Printing for large runs with simple, bold designs.
Opt for DTG when printing detailed, colorful artwork on cotton in small quantities.
Use Heat Transfer for quick, on-demand customizations with minimal setup.

100% Cotton vs. Tri-Blends vs. Polyester: Your Guide to Choosing Fabrics for a Custom T-Shirt Maker

Choosing the right fabric is crucial when creating custom t-shirts. The material impacts comfort, durability, print quality, and overall customer satisfaction. Here’s a breakdown of the three most popular choices: 100% Cotton, Tri-Blends, and Polyester.

100% Cotton

Pros:
– Soft and Breathable: Offers a classic, comfortable feel perfect for everyday wear.
– Natural Fiber: Highly breathable, making it ideal for warm weather and active use.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.
– Great for Printing: Absorbs ink well, resulting in vibrant, crisp prints—especially with screen printing.

Cons:
– Prone to Shrinkage: Can shrink if not pre-shrunk or washed improperly.
– Less Durable Over Time: May wear out faster with frequent washing and show pilling.
– Wrinkles Easily: Tends to wrinkle more than synthetic blends.
– Absorbs Moisture: Holds sweat and takes longer to dry.

Best For: Casual wear, promotional shirts, screen-printed designs, eco-conscious customers.

Tri-Blend (Typically Cotton, Polyester, Rayon)

Pros:
– Ultra-Soft Feel: Combines the softness of cotton with the smoothness of rayon and durability of polyester.
– Excellent Drape: Offers a slightly fitted, vintage-inspired look that moves well with the body.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic content.
– Fade-Resistant: Holds color well over time, even after multiple washes.

Cons:
– Higher Cost: Generally more expensive than 100% cotton or polyester.
– Less Breathable Than Cotton: The polyester and rayon content can reduce breathability slightly.
– Not Ideal for Heavy Prints: Some printing methods may not adhere as well; requires testing.

Best For: Fashion-forward apparel, premium tees, vintage-style designs, lightweight garments.

Polyester

Pros:
– Durable & Long-Lasting: Resistant to shrinking, stretching, and wrinkles.
– Moisture-Wicking: Draws sweat away from the body, making it ideal for activewear.
– Quick-Drying: Excellent for performance and sports apparel.
– Color Retention: Holds vibrant dye-sublimation prints exceptionally well.

Cons:
– Less Breathable: Can feel clammy or hot in warm conditions.
– Prone to Static & Pilling: May develop static electricity and surface fuzz over time.
– Environmental Concerns: Made from petroleum; not biodegradable.
– Feel: Can feel less “natural” or softer compared to cotton or tri-blends.

Best For: Athletic wear, outdoor events, sublimation printing, all-over print designs, uniforms.

Choosing the Right Fabric for Your Custom T-Shirt Project

Consider these factors when deciding:
– Intended Use: Is it for casual wear, sports, or fashion?
– Printing Method: Screen printing favors cotton; sublimation requires polyester.
– Target Audience: Are they eco-conscious, fashion-focused, or performance-oriented?
– Budget: Tri-blends and performance polyesters often cost more than basic cotton.
– Comfort vs. Performance: Prioritize breathability (cotton) or moisture management (polyester).

By understanding the strengths and weaknesses of 100% cotton, tri-blends, and polyester, you can make a smart, customer-focused choice for your custom t-shirt line.

How to Get the Best Price for a Custom T-Shirt Maker (Bulk Discounts & Artwork Preparation Tips)

Getting high-quality custom t-shirts at the best possible price involves smart planning, especially when ordering in bulk. Whether you’re designing shirts for an event, business, or promotion, these tips will help you save money while ensuring professional results.

Leverage Bulk Discounts Effectively

One of the easiest ways to reduce per-unit costs is by ordering in larger quantities. Here’s how to maximize your savings:

• Order in Larger Quantities: Most custom t-shirt printers offer tiered pricing—larger orders mean lower prices per shirt. For example, ordering 200 shirts may be significantly cheaper per unit than ordering 50.

• Consolidate Designs: If you need multiple designs, consider limiting variations. Printing the same design across more shirts qualifies you for bulk pricing. If you must have multiple designs, group them by print location and color count to reduce setup fees.

• Choose Standard Sizes and Colors: Stick to popular t-shirt colors (like black, white, or navy) and standard sizes (S–XXL). Specialty colors or extended sizes can increase costs.

• Compare Multiple Vendors: Get quotes from several reputable custom t-shirt makers. Look beyond price—consider quality, turnaround time, and customer service. Online platforms like Printful, Custom Ink, or local screen printers often have competitive bulk pricing.

• Time Your Order: Avoid peak seasons (e.g., back-to-school, holidays). Ordering during slower periods may give you better rates or faster turnaround times.

Optimize Artwork Preparation to Save Money

Proper artwork setup can reduce printing complexity and costs. Follow these best practices:

• Use High-Resolution Files: Supply vector files (AI, EPS, SVG) or high-res PNG/JPG (300 DPI). Low-quality images may require redesigns, adding extra fees.

• Limit Print Colors: Each additional color in a design increases screen setup costs in screen printing. Opt for one- or two-color designs when possible. For full-color designs, consider direct-to-garment (DTG) printing, which may be cost-effective for smaller runs.

• Simplify Your Design: Avoid intricate details that may not print well or require expensive techniques. Bold, clean graphics print better and cost less.

• Confirm Print Area and Placement: Standard print locations (center chest, left chest, or full back) are cheaper than custom placements. Specify exact positioning to avoid misprints and reprints.

• Provide Color Codes: Use Pantone (PMS) or CMYK/RGB values to ensure accurate color matching. This prevents costly corrections and reprints due to color mismatches.

• Review a Print Proof: Always request a digital or physical proof before full production. Catching errors early avoids expensive re-runs.

By combining smart bulk ordering strategies with professional artwork preparation, you can achieve high-quality custom t-shirts at the best possible price. Plan ahead, communicate clearly with your printer, and prioritize simplicity to maximize savings.