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

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

Choosing the right fabric is crucial when working with custom t-shirt manufacturers. The material impacts comfort, durability, print quality, drape, and overall customer satisfaction. Here’s a breakdown of the three most popular options to help you make the best decision for your brand or project.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, soft feel that’s ideal for everyday wear, especially in warmer weather.
– Excellent for Printing: Absorbs water-based and plastisol inks well, resulting in vibrant, crisp prints.
– Eco-Friendly Option: Biodegradable and widely recyclable, appealing to sustainability-focused customers.
– Classic Look and Feel: Preferred by customers who appreciate the traditional t-shirt experience.

Cons:
– Prone to Shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable: More susceptible to pilling and wear over time compared to blended fabrics.
– Wrinkles Easily: Requires ironing or steaming to maintain a neat appearance.
– Absorbs Moisture: While breathable, it holds onto sweat, which may feel damp during high activity.

Best For: Casual wear, fashion-forward brands, eco-conscious lines, and customers who prioritize natural fibers and comfort.

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

Pros:
– Durability: Polyester adds strength, making the fabric more resistant to shrinking, pilling, and wear.
– Wrinkle and Shrink Resistance: Holds its shape and appearance better after repeated washing.
– Affordable: Often less expensive than 100% cotton or tri-blends.
– Moisture-Wicking: Polyester helps wick moisture away, making it suitable for light activity or warmer climates.

Cons:
– Less Soft: Can feel slightly rougher or less breathable than 100% cotton, especially in hot conditions.
– Prone to Pilling: While more durable, the cotton component can still pill over time.
– Print Quality Variance: May not absorb inks as smoothly as 100% cotton, potentially leading to slightly less vibrant or softer prints.

Best For: Budget-friendly promotional shirts, retail basics, event giveaways, and products that need to balance cost, durability, and comfort.

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

Pros:
– Luxurious Feel: Combines softness from cotton and rayon with the durability of polyester for a silky, vintage-like hand feel.
– Excellent Drape: Flows beautifully and conforms to the body, ideal for fashion-oriented designs.
– Reduced Shrinkage: More stable than 100% cotton, especially when cared for properly.
– Vintage Aesthetic: Develops a worn-in, heathered look over time that many consumers love.

Cons:
– Higher Cost: More expensive due to the inclusion of rayon and specialized manufacturing.
– Less Durable Under Stress: Rayon is weaker when wet, so excessive washing or rough handling can lead to faster wear.
– Special Care Required: May require gentle washing and air drying to maintain quality.
– Printing Challenges: Requires careful ink selection and curing techniques to avoid cracking or fading.

Best For: Premium apparel lines, fashion brands, boutique labels, and customers seeking a high-end, soft, and stylish t-shirt.

Final Tips for Working with Custom T-Shirt Manufacturers

• Request Fabric Samples: Always get physical swatches to assess texture, weight, and drape before placing bulk orders.
• Discuss Print Methods: Inform your manufacturer of your design (e.g., screen print, DTG, sublimation) so they can recommend the best fabric.
• Consider End Use: Think about who will wear the shirt and how—athletic use, everyday wear, or fashion statements all require different fabrics.
• Ask About Pre-Shrinking: Ensure fabrics are pre-shrunk to minimize post-wash size changes.

By understanding the strengths and limitations of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the right fabric that aligns with your brand’s values, target audience, and design goals.

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

When ordering custom t-shirts in bulk, securing the best price requires smart planning, strategic ordering, and clear communication with manufacturers. Here’s how to maximize savings through quantity breaks and artwork efficiency.

Leverage Bulk Quantity Breaks

One of the most effective ways to reduce per-unit costs is by taking advantage of bulk pricing tiers offered by manufacturers.

• Order at Tier Thresholds: Most suppliers offer lower prices at specific quantity thresholds (e.g., 50, 100, 250, 500, 1000+ units). Always aim to order at or just above these thresholds—ordering 101 shirts instead of 100 can drop your price significantly.

• Consolidate Orders: If possible, combine multiple small orders into one large purchase. This increases your volume and qualifies you for better pricing.

• Negotiate for Larger Runs: For orders over 500 or 1,000 units, contact the manufacturer directly to negotiate custom pricing. Many are willing to offer additional discounts for high-volume commitments.

• Consider Blank Inventory: Some manufacturers allow you to buy blank shirts at wholesale rates and print later. This spreads out costs and gives you flexibility while still benefiting from bulk savings.

Optimize Artwork for Cost Efficiency

High-quality artwork is essential, but smart design choices can reduce printing costs and speed up production.

• Simplify Your Design: Fewer colors mean lower printing costs, especially with screen printing. Stick to 1–3 colors when possible. Each additional color adds setup time and expense.

• Use Vector Files: Provide artwork in vector format (e.g., .AI, .EPS, or .PDF) for crisp, scalable prints. Raster images (like JPEGs) may require redrawing, which can incur extra fees.

• Minimize Print Areas: Smaller or single-location prints (e.g., left chest or center back) are cheaper than large, multi-panel designs. Avoid all-over prints unless necessary.

• Standardize Sizes and Colors: Ordering in fewer shirt colors and standard sizes reduces setup complexity and material waste. Mixed colors or specialty fabrics often cost more.

• Approve a Physical Proof: Request a physical or digital proof before full production. Fixing errors early avoids costly reprints.

Choose the Right Printing Method

Different printing techniques vary in cost and suitability for bulk orders.

• Screen Printing: Most cost-effective for large quantities (50+) with simple, bold designs. High setup cost, but low per-unit price at scale.

• DTG (Direct-to-Garment): Better for complex, full-color designs or small batches. Higher per-shirt cost, less ideal for very large orders.

• Heat Transfer or Sublimation: Suitable for detailed graphics but may not be durable or cost-effective at scale. Best for specialty items like performance wear.

Build Relationships with Suppliers

Long-term partnerships can lead to better pricing and priority service.

• Request Quotes from Multiple Vendors: Compare pricing, quality, and turnaround times. Don’t assume the lowest quote is best—check reviews and sample quality.

• Ask About Discounts: Inquire about seasonal promotions, first-time buyer discounts, or loyalty programs.

• Provide Clear Specs: Accurate size counts, fabric types, and delivery timelines help avoid delays and change fees.

By planning ahead, maximizing order quantities, optimizing artwork, and choosing the right printing method, you can significantly reduce costs while maintaining high-quality custom t-shirts.