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

| Feature | Screen Printing | DTG (Direct-to-Garment) | Heat Transfer |
|—————————-|——————————————|——————————————|—————————————-|
| Best For | Large orders, simple designs, durability | Small orders, detailed/full-color designs | Small batches, quick turnaround, DIY |
| Setup Time & Cost | High setup cost and time (per color) | Minimal setup, low cost | Very low setup, fast preparation |
| Print Quality | Vibrant, opaque, thick feel | Photorealistic, soft hand feel | Varies; can feel plasticky or soft |
| Color Detail | Limited by number of screens/colors | Excellent; unlimited colors, gradients | Excellent; handles full-color designs |
| Fabric Compatibility | Works best on cotton; limited on blends | Best on 100% cotton; struggles with synthetics | Works on most fabrics, including blends |
| Durability | Very durable; long-lasting washes | Good; may fade after many washes | Varies; can crack or peel over time |
| Cost Efficiency | Economical for large runs (>50 units) | Cost-effective for small runs (<50 units)| Low upfront cost; higher per-unit cost |
| Production Speed | Fast once set up; slow for small runs | Slower per piece; no setup delays | Fast for small quantities |
| Design Flexibility | Changes require new screens (expensive) | Easy design changes; no additional cost | Easy to change designs instantly |
| Environmental Impact | Uses more water and chemicals | Uses water-based inks; more eco-friendly | Varies; some use plastisol or sublimation |
| Ideal Use Cases | Bulk orders, logos, solid colors | Complex artwork, photos, low quantities | Prototypes, events, custom one-offs |

This table helps determine the best method based on order size, design complexity, budget, and fabric type.

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

Choosing the right fabric is crucial for the look, feel, and durability of your custom printed t-shirts. The three most common options—100% cotton, tri-blends, and polyester—each offer distinct advantages and drawbacks. Understanding their differences helps you make the best choice for your project.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and Comfortable: Offers a natural, soft hand feel that many people love, especially in heavier weights.
– Highly Breathable: Excellent for warm weather or active wear due to its ability to absorb moisture and allow air circulation.
– Great Print Canvas: Works exceptionally well with screen printing and direct-to-garment (DTG) methods, producing vibrant, crisp designs.
– Eco-Friendly Appeal: Biodegradable and often perceived as a more sustainable option, especially when organic cotton is used.

Cons:
– Prone to Shrinking: Can shrink significantly if not pre-shrunk or washed improperly.
– Less Durable Over Time: May wear out faster, pill, or lose shape after repeated washes.
– Wrinkles Easily: Requires ironing or steaming to maintain a crisp appearance.

Best For: Casual wear, promotional shirts, vintage-style graphics, and customers who prioritize comfort and natural fibers.

Tri-Blends: The Best of Both Worlds

Pros:
– Super Soft and Lightweight: Typically made from a blend of cotton, polyester, and rayon, tri-blends offer a buttery-soft feel with a slightly heathered look.
– Excellent Drape: Drapes beautifully on the body, making them ideal for fashion-forward or fitted styles.
– Reduced Shrinkage: More stable than 100% cotton due to the synthetic fibers.
– Great Print Results: Ideal for DTG printing, producing soft, vintage-inspired designs with good color saturation.

Cons:
– Less Breathable: Not as breathable as 100% cotton due to polyester content.
– Slightly Less Durable: Can be more delicate and prone to pilling or snagging.
– Higher Cost: Usually more expensive than 100% cotton or polyester options.

Best For: Fashion apparel, women’s cuts, boutique-style tees, and designs with a soft, worn-in aesthetic.

Polyester: Performance and Durability

Pros:
– Highly Durable: Resistant to shrinking, stretching, and wrinkling. Maintains shape and appearance over time.
– Moisture-Wicking: Pulls sweat away from the skin, making it ideal for athletic or performance wear.
– Quick-Drying: Dries much faster than cotton, perfect for activewear or humid climates.
– Colorfast: Holds dyes well and resists fading, especially with sublimation printing.

Cons:
– Less Breathable: Can feel clammy or hot in warm conditions due to limited moisture absorption.
– Prone to Odor Retention: May hold onto body odor more than natural fibers unless treated with anti-microbial finishes.
– Can Feel Synthetic: Some people find polyester less comfortable against the skin due to its plastic-like texture.

Best For: Sportswear, outdoor events, workwear, and all-over sublimation prints (e.g., full-coverage designs on performance tees).

Making the Right Choice

Consider these factors when deciding:
– Intended Use: Is it for everyday wear, sports, or fashion?
– Climate: Will the shirt be worn in hot, humid, or active environments?
– Design Complexity: Are you using detailed, full-color designs (better on tri-blends or polyester) or simple logos (great on cotton)?
– Budget: Tri-blends and performance polyester often cost more than basic cotton.
– Sustainability Goals: Cotton is biodegradable; recycled polyester offers eco-benefits too.

By matching the fabric to your audience and purpose, you’ll ensure your custom t-shirts look great, feel comfortable, and stand the test of time.

How to Get the Best Price for Custom T-Shirt Printing

Getting custom t-shirts for your team, event, or business doesn’t have to break the bank. With smart planning and the right strategies—especially around bulk discounts and artwork preparation—you can secure high-quality prints at the best possible price. Here’s how.

Leverage Bulk Discounts Effectively

One of the most powerful ways to reduce per-unit costs is by ordering in bulk. Most printing companies offer tiered pricing, where the price per shirt decreases as your order quantity increases.

• Order More Units: Aim for minimum thresholds that trigger lower pricing tiers (e.g., 50, 100, 250+ units). Even increasing your order by a few extra shirts can move you into a better pricing bracket.
• Consolidate Orders: If multiple groups or departments need shirts, combine orders to reach higher volume discounts.
• Plan Ahead: Bulk orders reduce long-term costs. If you anticipate future needs, consider placing a larger order now instead of multiple small ones.
• Compare Tiered Pricing: Request detailed price breakdowns from multiple vendors. Some companies offer steeper discounts at higher volumes, while others might be more competitive at lower quantities.

Optimize Artwork Preparation to Save Money

High-quality, print-ready artwork not only ensures a professional result but also avoids costly delays and revisions.

• Use Vector Files (AI, EPS, SVG): Vector graphics scale infinitely without losing quality and are preferred for screen printing and embroidery. Submitting vector artwork reduces setup time and potential errors.
• Provide High-Resolution Raster Images (300 DPI): If using PNG or JPG, ensure images are at least 300 dots per inch (DPI) at the intended print size to avoid pixelation.
• Simplify Your Design: Fewer colors and simpler designs reduce printing complexity. For screen printing, each additional color increases setup and labor costs. Stick to 1–3 colors when possible.
• Use Spot Colors (Pantone): Specify Pantone colors for consistent color matching. This avoids time-consuming color adjustments and reprints.
• Submit Artwork Early: Give your printer plenty of time to review and request changes. Rushing artwork can lead to mistakes or additional fees.
• Follow the Printer’s Template: Use provided design templates for layout, bleed, and safe zones to avoid cropping or misalignment issues.

By combining bulk ordering with professionally prepared artwork, you’ll not only save money but also ensure a smoother, faster production process. Take the time to compare quotes and review print specs—your budget and your team will thank you.