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

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

When creating custom printed t-shirts, selecting the right fabric is just as important as the design itself. The material affects comfort, durability, print quality, and overall feel. Three of the most popular options—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits. Here’s a breakdown to help you choose the best fabric for your custom printing needs.

100% Cotton: Classic Comfort and Softness

Pros:
– Soft and Breathable: Pure cotton is naturally soft, breathable, and ideal for warm weather or active wear.
– Eco-Friendly Option: Cotton is a natural, biodegradable fiber, making it a go-to choice for environmentally conscious buyers.
– Excellent Print Surface: Provides a smooth, consistent base that works well with screen printing and direct-to-garment (DTG) printing, especially for bold, vibrant designs.
– Widely Available: Comes in a range of weights (e.g., 5.3 oz, 6.1 oz) and styles (e.g., ringspun for extra softness).

Cons:
– Prone to Shrinking: Especially if not pre-shrunk, cotton can shrink after washing.
– Less Durable Over Time: May wear out faster than blended fabrics, particularly with frequent washing.
– Wrinkles Easily: Requires ironing or steaming for a crisp look.

Best For: Everyday wear, promotional shirts, retail apparel, and customers who prioritize natural fibers and softness.

50/50 Blend: Cotton-Polyester Balance

Pros:
– Durable and Long-Lasting: The 50% polyester adds strength and resistance to wear and tear.
– Less Shrinkage: Blended fabric is more stable and resists shrinking compared to 100% cotton.
– Budget-Friendly: Often more affordable than tri-blends and offers a good middle ground in price and performance.
– Good Print Compatibility: Works well with most printing methods, including screen printing and DTG.

Cons:
– Slightly Less Soft: Can feel a bit stiffer than 100% cotton, especially in lower-quality blends.
– Less Breathable: Polyester doesn’t breathe as well as cotton, which may make it feel warmer.
– Pilling Risk: Over time and with friction, the fabric may develop small fabric balls (pilling).

Best For: Workwear, event shirts, school apparel, and customers seeking durability without sacrificing too much comfort.

Tri-Blend: The Premium Soft-Touch Option

Pros:
– Ultra-Soft Feel: Typically made from a blend of cotton, polyester, and rayon (e.g., 50/25/25), tri-blends have a silky, vintage-soft texture.
– Excellent Drape: Drapes beautifully on the body, giving a more fitted and stylish look.
– Minimal Shrinkage: The polyester and rayon help stabilize the fabric.
– Vintage Aesthetic: The fabric ages well and develops a worn-in look that many find appealing.
– Great for DTG Printing: The blend absorbs ink beautifully, making it ideal for detailed, full-color designs.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Less Durable for Heavy Use: Not ideal for rugged work environments or high-abrasion use.
– Sensitivity to Heat: Requires lower washing and drying temperatures to avoid damage.

Best For: Fashion-forward apparel, boutique brands, gift items, and customers who value softness and a modern, stylish appearance.

How to Choose the Right Fabric

Consider these factors when deciding:
– Intended Use: Is it for daily wear, events, or promotional giveaways?
– Target Audience: Are they eco-conscious, fashion-focused, or need durable workwear?
– Printing Method: DTG prints shine on tri-blends, while screen printing works well on all three.
– Budget: Tri-blends cost more; 50/50 blends offer a cost-effective balance.
– Care Instructions: Will the wearer follow special care guidelines, or do they need low-maintenance fabric?

By matching your fabric choice to your goals and audience, you 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 Prints (Bulk Quantity Breaks, Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To maximize savings and ensure quality, it’s essential to understand bulk pricing structures and optimize your design process. Here’s how to get the best deal:

Leverage Bulk Quantity Breaks Strategically

Most print shops offer tiered pricing—larger orders cost less per shirt. Use these breaks to your advantage:

• Know the Break Points: Common quantity tiers are 25, 50, 100, 250, and 500+. Prices drop significantly at each threshold. For example, 100 shirts might cost $8 each, while 250 drop to $5 each.
• Consolidate Orders: If you’re unsure about exact needs, round up to the next pricing tier. It’s often cheaper to order extra shirts now than to reorder later at a higher per-unit cost.
• Consider Future Needs: Order slightly more than you need to cover replacements or future use. Storage is usually cheaper than reordering.
• Compare Vendors: Not all companies have the same break points. Get quotes from multiple suppliers and look for those with lower minimums or steeper discounts.

Optimize Your Artwork to Reduce Costs

Design choices directly impact printing expenses. Simple, well-prepared artwork saves money:

• Simplify Your Design: Fewer colors = lower printing costs. Each additional color increases setup time and ink use. Stick to 1–3 colors whenever possible.
• Use Vector Files: Provide logos or graphics in vector formats (AI, EPS, SVG). They scale without quality loss and reduce prep time, avoiding extra fees for file conversion.
• Avoid Photographic Prints for Large Runs: Full-color, photo-like prints often require costly printing methods like direct-to-garment (DTG). For bulk orders, screen printing is cheaper—design accordingly.
• Design for One Print Location: Printing on the front only is cheaper than front and back. If you must print on both sides, plan for higher costs.
• Check Color Matching: Use standard PMS colors or let the printer match from their in-house palette to avoid custom ink mixing fees.

Additional Cost-Saving Tips

• Choose Affordable Garments: High-end brands (e.g., Bella+Canvas 3001) cost more. Consider value-line blanks (e.g., Gildan 5000) for budget-conscious projects.
• Stick to One Shirt Style & Color: Mixing styles or colors increases setup time and inventory complexity, raising costs.
• Order Off-Peak: Avoid holiday seasons and back-to-school rushes when demand (and prices) spike.
• Negotiate with Suppliers: For large orders (500+), ask for discounts or free setup fees—many vendors are willing to negotiate.

By planning your order size around quantity breaks and preparing print-ready artwork, you’ll significantly reduce per-unit costs and get the best value for your custom t-shirts.