Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

Guide to Choosing Fabrics for Custom T-Shirt Print: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

When designing custom t-shirts, the fabric you choose plays a crucial role in comfort, durability, print quality, and overall appeal. Understanding the differences between popular fabric types—100% cotton, 50/50 blends, and tri-blends—can help you make the best choice for your project. Here’s a detailed comparison to guide your decision.

100% Cotton

Pros:
– Soft and Breathable: Natural fibers make 100% cotton highly breathable, ideal for warm weather and everyday wear.
– Comfortable Feel: Offers a classic, soft hand feel that many people prefer.
– Eco-Friendly Option: Biodegradable and often available in organic varieties, appealing to environmentally conscious buyers.
– Great for Printing: Holds ink well, especially with screen printing and direct-to-garment (DTG) methods, producing vibrant, crisp designs.

Cons:
– Prone to Shrinking: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable: More susceptible to wear, pilling, and fading over time.
– Wrinkles Easily: Requires ironing or steaming for a polished appearance.
– Absorbs Moisture: While breathable, it retains sweat and takes longer to dry.

Best For: Casual wear, promotional events, eco-conscious brands, and designs requiring high print clarity.

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

Pros:
– Durability: Polyester adds strength, reducing pilling and increasing longevity.
– Reduced Shrinking: More stable in the wash compared to 100% cotton.
– Wrinkle-Resistant: Holds its shape better and resists creasing.
– Moisture-Wicking: Polyester helps wick moisture, making it slightly more performance-oriented.
– Cost-Effective: Often more affordable than tri-blends and high-end cotton.

Cons:
– Less Breathable: Reduced airflow compared to pure cotton, which may feel warmer.
– Slight Sheen: Polyester can give the fabric a subtle shine, which may not suit matte print finishes.
– Pilling Over Time: While better than cotton, it can still develop surface fuzz with heavy use.

Best For: Workwear, giveaways, sports teams, and high-volume orders where durability and cost are key factors.

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

Pros:
– Ultra-Soft Feel: Combines the softness of cotton, durability of polyester, and drape of rayon for a luxurious, vintage-inspired texture.
– Excellent Drape: Flatters the body and moves smoothly, ideal for fitted or fashion-forward styles.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic fibers.
– Fade-Resistant: Withstands repeated washing without significant color loss.
– Unique Aesthetic: Offers a heathered or mélange look that complements trendy, lifestyle branding.

Cons:
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Delicate Printing: Requires careful handling during printing; not all ink types adhere as well.
– Less Breathable Than Cotton: The synthetic content can reduce airflow, though rayon helps balance this.
– Not Ideal for Heavy Use: May not withstand industrial laundering or extreme wear.

Best For: Fashion apparel, boutique brands, gift items, and premium custom tees where softness and style are priorities.

Final Tips for Choosing Your Fabric

• Consider the Use Case: Will the shirts be worn daily, for sports, or as keepsakes? Match the fabric to the activity.
• Think About Print Method: DTG printing works well on cotton and tri-blends, while screen printing is versatile across all three.
• Evaluate Budget: 100% cotton and 50/50 blends are generally more budget-friendly; tri-blends offer a premium upgrade.
• Prioritize Comfort vs. Durability: Cotton is softer, but blends last longer. Tri-blends offer a balance with a fashion edge.

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

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team – but only if you know how to maximize savings. By understanding bulk pricing structures and optimizing your artwork, you can significantly reduce your per-unit cost without sacrificing quality.

Understand Bulk Quantity Breaks

Most print shops offer tiered pricing based on order volume. The more shirts you order, the lower the price per shirt. Knowing how these breaks work is key to getting the best deal.

• Know the Standard Tiers: Common quantity breaks are 12, 24, 50, 100, 250, and 500 units. For example, 48 shirts might cost $10 each, but ordering 50 could drop the price to $7 each.
• Order Just Above the Breakpoint: If 50 shirts give a big discount, consider ordering 51 instead of 49. The small increase in total cost often yields major per-unit savings.
• Plan for Future Needs: If you anticipate needing more shirts later, it’s often cheaper to order a larger batch now. Storage is usually cheaper than reordering at a smaller quantity.
• Combine Designs: Some vendors allow different designs on the same order while still qualifying for bulk pricing. Coordinate with teams or departments to combine orders.

Choose the Right Printing Method

The printing technique affects both cost and quality. Select one that matches your design complexity and volume.

• Screen Printing: Most cost-effective for large orders (50+ units) with simple, limited-color designs. Setup costs are high, but per-unit cost drops significantly with volume.
• DTG (Direct-to-Garment): Best for detailed, full-color designs or small batches. No setup fees, but higher per-shirt cost. Not ideal for bulk savings.
• Dye Sublimation: Great for all-over prints on polyester. Best for larger runs and vibrant designs.
• Heat Transfer: Suitable for small runs or complex designs, but less durable and not ideal for large orders.

Optimize Your Artwork for Cost Savings

Your design choices directly impact printing costs. Smart artwork preparation keeps quality high and expenses low.

• Simplify Your Design: Fewer colors = lower screen printing costs. Stick to 1–3 colors when possible.
• Use Vector Files: Provide logos and artwork in vector format (AI, EPS, SVG) for crisp scaling and professional printing. Avoid low-resolution JPGs.
• Follow Print Guidelines: Adhere to the printer’s size, placement, and bleed specifications to avoid rework fees or delays.
• Limit Print Locations: Printing on one side (usually the front) is cheaper. Adding a back or sleeve print increases setup and labor costs.
• Stick to Standard Sizes: Custom dimensions or unusual placements may incur extra fees.

Compare Multiple Vendors

Never settle for the first quote. Shop around and leverage competition.

• Request Detailed Quotes: Ensure quotes include setup fees, printing costs, blank garment cost, and shipping.
• Look for Promotions: Many printers offer seasonal discounts, free setups, or waived fees for first-time bulk orders.
• Check Reviews and Samples: Quality matters. Order a sample pack to assess fabric and print before committing to bulk.

Final Tips for Maximum Savings

• Choose Affordable Blank Shirts: Premium brands cost more. Opt for value-priced, good-quality blanks (e.g., Gildan, Bella+Canvas 3001) unless branding demands otherwise.
• Avoid Rush Fees: Plan ahead. Standard turnaround is cheaper than rush processing.
• Negotiate: For large orders (250+), don’t hesitate to ask for a better price, free revisions, or waived fees.

By leveraging quantity breaks, choosing the right print method, and preparing professional artwork, you can achieve high-quality custom t-shirts at the lowest possible price. Smart planning today leads to big savings tomorrow.