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

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

When ordering custom t-shirts online, one of the most important decisions you’ll make is the fabric. The material affects how the shirt feels, fits, prints on, and holds up over time. The three most popular choices are 100% cotton, 50/50 cotton-polyester blends, and tri-blend fabrics. Here’s a breakdown to help you choose the best option for your needs.

100% Cotton: Classic Comfort and Breathability

100% cotton t-shirts are a timeless favorite for good reason. Made entirely from natural cotton fibers, they offer softness, breathability, and a comfortable feel against the skin.

Pros:
– Soft and breathable: Ideal for warm weather and all-day wear.
– Great for printing: Absorbs ink well, resulting in vibrant, crisp prints—especially with screen printing or water-based inks.
– Natural feel: Preferred by those who avoid synthetic materials.
– Eco-friendly option: Biodegradable and often available in organic varieties.

Cons:
– Prone to shrinking: May shrink after washing, especially if not pre-shrunk.
– Less durable: Can wear out faster than blended fabrics, especially with frequent washing.
– Wrinkles easily: Requires more care to maintain a neat appearance.
– Absorbs moisture: Holds sweat, which may feel damp during physical activity.

Best for: Everyday wear, casual events, eco-conscious brands, and designs requiring bold, detailed prints.

50/50 Blend: The Balanced Performer

A 50/50 blend combines equal parts cotton and polyester, offering a middle ground between comfort and durability.

Pros:
– Durable and long-lasting: Resists wear and fading better than 100% cotton.
– Less shrinkage: Holds its shape well after multiple washes.
– Moisture-wicking: Polyester helps draw sweat away from the skin.
– Affordable: Often priced lower than tri-blends and premium cottons.

Cons:
– Slightly less soft: May feel a bit stiffer than 100% cotton, especially at first.
– Less breathable: Polyester reduces airflow compared to pure cotton.
– Ink absorption: Can be trickier to print on; plastisol inks work best, but prints may feel heavier.

Best for: Promotional giveaways, workwear, school events, and active use where durability matters.

Tri-Blend: Softness and Style Combined

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

Pros:
– Ultra-soft feel: Often described as “buttery” or “vintage-soft” right from the start.
– Lightweight and drapey: Flatters the body with a relaxed, modern fit.
– Reduced shrinkage: Stable after washing due to synthetic fibers.
– Vintage aesthetic: The heathered texture gives a stylish, worn-in look.

Cons:
– Higher cost: Usually more expensive than cotton or 50/50 options.
– Delicate fabric: Can be less durable and prone to pilling with heavy use.
– Printing considerations: Requires precise techniques; water-based or discharge inks work best for soft-hand prints.
– Not ideal for heavy designs: Large solid prints may stiffen the fabric.

Best for: Fashion-forward brands, boutique apparel, gift items, and designs emphasizing comfort and aesthetic appeal.

How to Choose the Right Fabric for Your Project

• For comfort and breathability: Choose 100% cotton.
• For durability and budget-friendly bulk orders: Go with a 50/50 blend.
• For softness, style, and a premium feel: Opt for a tri-blend.

Consider your audience, use case, design complexity, and budget when making your decision. Most online custom t-shirt printers provide fabric samples—ordering one can help you feel the differences firsthand before placing a large order.

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

Ordering custom t-shirts in bulk online can be cost-effective, but maximizing savings requires strategy. Here’s how to secure the best price while ensuring top-quality results.

Leverage Bulk Quantity Breaks Strategically

Suppliers offer lower per-unit prices as order quantities increase. Understanding and using these breaks is key to saving money.

• Know the Thresholds: Most printers have tiered pricing (e.g., 12–24, 25–49, 50–99, 100+). The biggest savings often start at 50 or 100 units. Always check the price per shirt at each tier.
• Order Just Over the Break Point: If 49 shirts cost $10 each but 50 cost $7 each, ordering 50 saves $147 total—far more than the cost of one extra shirt. Calculate the break-even point before deciding.
• Consider Future Needs: If you anticipate needing more shirts later, ordering a larger batch now can reduce long-term costs and shipping fees.
• Consolidate Designs: If possible, minimize the number of unique designs. Ordering 100 shirts with one design is cheaper than 50 shirts with two different designs due to setup costs.

Choose the Right Printing Method for Your Design

Different printing techniques vary in cost and suitability. Matching the method to your design ensures quality and affordability.

• Screen Printing: Best for large quantities (50+) and simple designs with few colors. Low per-unit cost after setup, but higher initial setup fee.
• DTG (Direct-to-Garment): Ideal for complex, full-color designs and smaller runs. No setup fees, but higher per-shirt cost. Prices drop slightly with volume, but not as dramatically as screen printing.
• Heat Transfer: Good for very small orders or highly detailed images. Can be less durable and more expensive per unit for bulk.
• Tip: Ask suppliers for quotes using multiple methods—sometimes DTG is competitive even for mid-sized runs with complex art.

Optimize Your Artwork to Reduce Costs

Simple, well-prepared artwork minimizes production time and errors, saving you money.

• Use Vector Files (AI, EPS, SVG): These scale infinitely without quality loss and are preferred by printers. They reduce processing time and prevent extra fees for artwork cleanup.
• Stick to Fewer Colors: For screen printing, each color requires a separate screen. Limiting to 1–3 colors significantly cuts setup and printing costs.
• Avoid Gradients and Photorealism for Screen Printing: These require simulated process printing, which increases complexity and cost. Use solid colors or opt for DTG instead.
• Provide High-Resolution Raster Files (300 DPI): If using PNG or JPG, ensure resolution is high enough to prevent pixelation. Low-res files may require costly recreation.
• Specify Exact Pantone (PMS) Colors: This ensures accurate color matching and prevents reprints due to color mismatches.

Compare Multiple Suppliers & Negotiate

Don’t settle for the first quote you receive.

• Get Quotes from 3–5 Reputable Printers: Compare not just price, but also minimum order quantities, turnaround time, and included services (e.g., free design help, shipping).
• Look for Promotions and Coupons: Many online printers offer first-time discounts, seasonal sales, or free shipping on bulk orders.
• Negotiate for Large Orders: If ordering 200+ shirts, contact sales reps directly. They may offer custom pricing, free upgrades, or waived setup fees.
• Factor in Shipping: Some “low” prices exclude shipping. Choose suppliers with flat-rate or free shipping for bulk orders.

Final Tips for Maximum Savings

• Choose Standard Shirt Colors: White or basic colors (black, navy) are cheaper than fashion or specialty colors.
• Pick Common Sizes: Avoid excessive size splits (e.g., too many 2XL or XS). Stick to S–L unless necessary.
• Review Proofs Carefully: Approve digital proofs before printing to avoid costly reprints due to errors.

By planning your quantity, simplifying your design, choosing the right method, and shopping smartly, you can get high-quality custom t-shirts at the best possible price.