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 Online

When designing custom t-shirts online, one of the most important decisions you’ll make is the fabric. The material impacts comfort, durability, print quality, and overall look. Here’s a breakdown of the three most popular options to help you choose the best one for your needs.

100% Cotton: Classic Comfort and Breathability

100% cotton t-shirts are the traditional favorite for good reason. Made entirely from natural cotton fibers, they offer unmatched softness, breathability, and moisture absorption.

Pros:
– Soft and Comfortable: Feels great against the skin, especially in warmer weather.
– Breathable: Allows air to circulate, helping to regulate body temperature.
– Great for Printing: Holds vibrant screen prints and direct-to-garment (DTG) inks well.
– Natural and Biodegradable: An eco-friendly choice compared to synthetic blends.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster with repeated washing and may pill over time.
– Wrinkles Easily: Requires ironing for a crisp look.

Best For: Everyday wear, casual events, eco-conscious buyers, and designs with bold, detailed prints.

50/50 Blend: The Best of Both Worlds

A 50/50 blend combines equal parts cotton and polyester, offering a balanced mix of comfort and performance.

Pros:
– Durable and Long-Lasting: Resists wear, fading, and pilling better than 100% cotton.
– Less Prone to Shrinking: Holds its shape well after multiple washes.
– Soft with a Slight Sheen: Offers cotton-like comfort with a smoother, more polished appearance.
– Affordable: Often priced lower than tri-blends.

Cons:
– Less Breathable: Polyester can trap heat, making it less ideal for hot climates.
– Can Feel Less Natural: Some people find the texture slightly synthetic.
– May Show Pilling Over Time: Especially with frequent friction.

Best For: Promotional giveaways, workwear, school events, and high-volume orders where durability and cost are key.

Tri-Blend: Softness Meets Performance

Tri-blend fabrics typically consist of cotton, polyester, and rayon (often in a 50/25/25 or similar ratio). This combination creates a luxuriously soft, lightweight, and slightly heathered look.

Pros:
– Extremely Soft: Often described as having a “buttery” or vintage feel.
– Lightweight and Drapes Well: Great for fitted or fashion-forward styles.
– Reduced Shrinkage: More stable than 100% cotton.
– Vintage Aesthetic: The heathered appearance gives a modern, trendy look.

Cons:
– Higher Price Point: More expensive than cotton or 50/50 options.
– Less Durable for Heavy Use: The rayon content can make it less resilient over time.
– Special Care Needed: May require gentler washing to maintain softness and shape.

Best For: Fashion-forward apparel, boutique brands, premium gifts, and designs aiming for a modern, soft, lived-in look.

How to Choose the Right Fabric Online

When ordering custom t-shirts online, keep these tips in mind:
– Know Your Audience: Are they looking for comfort, durability, or style?
– Consider the Use Case: Will the shirt be worn daily, for events, or as a keepsake?
– Check Print Methods: Some fabrics work better with specific printing techniques (e.g., DTG vs. screen printing).
– Read Product Descriptions Carefully: Look for weight (e.g., 4.5 oz vs. 6.1 oz), pre-shrunk status, and care instructions.
– Order Samples: Many online printers offer sample packs—try before you buy in bulk.

By understanding the differences between 100% cotton, 50/50 blends, and tri-blends, you can confidently select the perfect fabric that aligns with your vision, budget, and customer expectations.

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

Ordering custom t-shirts in bulk online can be cost-effective, but getting the best price requires smart planning. Here’s how to maximize savings through bulk discounts and efficient artwork.

Understand Bulk Quantity Breaks

Most online printers offer tiered pricing—larger orders cost less per shirt. To leverage this:

• Know the Break Points: Common quantity tiers are 25, 50, 100, 250, and 500+. Prices often drop significantly at 100+ units.
• Order Just Over the Threshold: If 99 shirts cost $10 each but 100 cost $7, ordering 100 saves money overall—even if you don’t need every shirt.
• Split Sizes Strategically: Stay within a single quantity tier by adjusting size distribution (e.g., more medium, fewer XL) instead of increasing total count.

Choose the Right T-Shirt Style and Brand

• Opt for Budget-Friendly Blanks: Basic 100% cotton or cotton-polyester blends (like Gildan, Hanes, or Bella+Canvas 3001) are cheaper than premium or specialty fabrics.
• Stick to One Style: Mixing shirt types increases setup and handling fees. Uniformity reduces costs.

Simplify Your Design for Lower Printing Costs

Printing method and design complexity heavily impact price:

• Use Fewer Colors: Each ink color adds a screen and setup fee. Stick to 1–3 colors if using screen printing.
• Reduce Print Locations: A single print (front only) is cheapest. Adding back, sleeve, or pocket prints increases cost.
• Consider Print Method Wisely:
• Screen Printing: Best for large orders with simple designs.
• DTG (Direct-to-Garment): Cost-effective for small batches or full-color designs but pricier per unit at scale.
• Heat Transfer: Good for complex art but less durable and not ideal for bulk.

Optimize Your Artwork for Production

Clean artwork reduces errors and reprints—saving money:

• Submit High-Resolution Files: Use 300 DPI at actual print size. Low-res images result in blurry prints and remake fees.
• Use Vector Art When Possible: Logos and text should be in SVG, EPS, or AI format for crisp scaling.
• Outline Fonts and Convert to Paths: Prevents font substitution issues during printing.
• Specify Pantone (PMS) Colors: Ensures color accuracy, avoiding costly reprints due to mismatched shades.
• Provide a Mockup: Helps confirm placement and sizing before production begins.

Get Multiple Quotes and Look for Hidden Fees

• Compare at Least 3–5 Printers: Use identical specs (shirt type, quantity, print method) for fair comparison.
• Watch for Add-Ons: Check if setup fees, shipping, taxes, or rush charges are included. Some vendors hide costs until checkout.
• Ask About Bundle Deals: Some suppliers offer discounts when combining t-shirts with hats, bags, or other apparel.

Order Samples First

• Request a Physical Proof: Pay for one sample shirt to check print quality, color, and fit. Prevents costly bulk reprints.
• Test Wash and Wear: Ensures durability and satisfaction before full production.

Time Your Order Strategically

• Avoid Rush Fees: Plan ahead—standard turnaround is cheaper than expedited production.
• Look for Seasonal Discounts: Some printers offer deals during slow periods (e.g., early winter or summer).

By combining smart bulk ordering, simplified artwork, and careful vendor selection, you can significantly reduce your per-unit cost and get the best value for your custom t-shirts.