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

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

When designing custom t-shirts, the fabric you choose impacts comfort, durability, print quality, and overall customer satisfaction. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends is key to making the right choice for your project. Here’s a breakdown of each option:

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, soft feel against the skin and excellent breathability, ideal for warm weather and everyday wear.
– Great for Printing: Absorbs inks well, providing vibrant and crisp results with screen printing and direct-to-garment (DTG) methods.
– Eco-Friendly Appeal: Biodegradable and preferred by customers who value natural fibers.

Cons:
– Prone to Shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable: More likely to wear out, pill, or lose shape over time compared to blended fabrics.
– Wrinkles Easily: Requires more ironing and care to maintain a neat appearance.

Best For: Casual wear, eco-conscious brands, vintage-style tees, and designs requiring bold, detailed prints.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Balanced Performance: Combines the softness of cotton with the durability and wrinkle resistance of polyester.
– Minimal Shrinkage: Holds its shape better after repeated washing.
– Affordable: Typically more budget-friendly than tri-blends while offering enhanced durability.

Cons:
– Less Breathable: Polyester content reduces breathability, which may feel warmer in hot weather.
– Slight Sheen: Polyester can give the fabric a subtle synthetic sheen, which may affect the look of prints.
– Pilling Potential: Can develop small fabric pills over time with frequent use.

Best For: Promotional apparel, event t-shirts, workwear, and situations where durability and cost are priorities.

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

Pros:
– Ultra-Soft Hand Feel: Known for a buttery-soft, lightweight texture that drapes beautifully—often compared to a vintage or premium feel.
– Excellent Drape: Flattering fit that moves well with the body, ideal for fashion-forward styles.
– Fade-Resistant: Polyester content helps retain color vibrancy after multiple washes.
– Low Shrinkage: Highly stable in the wash with minimal shrinking.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends.
– Less Durable for Heavy Use: Softer fabric may be less resilient for rugged wear or industrial settings.
– Special Care Required: May require gentler washing (cold water, inside-out) to maintain softness and prevent pilling.

Best For: Premium branded apparel, fashion tees, boutique designs, and customers seeking a luxurious, soft hand feel.

Final Tips for Choosing

• Consider Your Audience: Are they looking for comfort, durability, or fashion?
• Think About Use Case: Everyday wear, events, retail sale, or promotional giveaways?
• Evaluate Print Needs: Detailed prints work well on cotton and tri-blends; bold designs hold up on 50/50.
• Budget Matters: Balance quality with cost—tri-blends offer luxury but at a higher price point.

By matching your fabric choice to your brand, design, and customer expectations, you’ll ensure your custom t-shirts look great, feel comfortable, and stand the test of time.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team—especially when you leverage quantity breaks and optimize your artwork. Here’s how to get the best possible price without sacrificing quality.

Take Advantage of Bulk Quantity Breaks

Most custom t-shirt printers offer tiered pricing based on order volume. Understanding these breaks is key to maximizing savings.

• Know the Thresholds: Common quantity breaks occur at 50, 100, 250, and 500+ units. Ordering just above the threshold (e.g., 101 instead of 99) can sometimes cost less per unit.
• Order More, Save More: The per-unit cost drops significantly as quantities increase. For example, 50 shirts might cost $8 each, while 250 could drop to $4.50.
• Consolidate Orders: If you anticipate future needs, combine orders to reach higher tiers and reduce long-term costs.

Choose the Right T-Shirt Style and Brand

Not all shirts are created equal—and pricing varies widely.

• Opt for Value-Focused Brands: Gildan, Hanes, and Alta Grande offer durable fabrics at lower price points compared to premium brands like Bella+Canvas.
• Stick to One Style: Ordering multiple styles increases setup and production complexity, which can raise costs.
• Standard Colors: White and black shirts are typically cheaper than specialty colors due to higher availability and lower ink requirements.

Minimize Print Complexity to Reduce Costs

Design complexity affects pricing more than you might think.

• Limit Print Locations: Each additional print location (front, back, sleeve) adds setup and printing fees. Stick to one or two locations.
• Reduce Number of Colors: Screen printing charges per color. A one- or two-color design is significantly cheaper than full-color prints.
• Use Simpler Artwork: Fine lines, gradients, and photorealistic details require advanced techniques (like DTG or four-color process), which cost more.

Prepare Print-Ready Artwork to Avoid Fees

Poor-quality artwork can lead to extra charges or delays.

• Use Vector Files: Provide logos or designs in vector format (AI, EPS, SVG) for crisp scaling and easy color separation.
• High-Resolution Raster Files: If using PNG or JPG, ensure 300 DPI at actual print size.
• Specify Pantone (PMS) Colors: This ensures color accuracy and avoids guesswork (and potential reprints).
• Simplify for Screen Printing: Break down complex designs into fewer spot colors. Avoid gradients unless necessary.

Compare Multiple Suppliers

Pricing and quality can vary drastically between vendors.

• Request Detailed Quotes: Compare not just the per-shirt cost, but also setup fees, ink colors, shipping, and turnaround time.
• Read Reviews: Check customer feedback on print quality, customer service, and delivery reliability.
• Ask About Discounts: Some suppliers offer first-time buyer discounts, nonprofit rates, or seasonal promotions.

Plan Ahead to Avoid Rush Fees

Rush orders can double production costs.

• Place Orders Early: Give yourself at least 2–3 weeks for standard production and shipping.
• Avoid Peak Seasons: Summer and back-to-school periods often see higher demand and pricing.

Consider All-Inclusive Pricing Models

Some modern online printers offer flat-rate pricing with no hidden fees.

• All-In Pricing: Look for services that include setup, unlimited ink colors (DTG), and shipping in one low price—ideal for complex designs or small runs.
• Transparency Matters: Avoid vendors with vague quotes. Clear breakdowns help you make informed decisions.

By leveraging bulk quantity breaks, simplifying your design, and preparing professional artwork, you can significantly reduce your custom t-shirt costs—without compromising on quality.