Comparison of Custom T-Shirt Printing Methods

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

Selecting the right fabric is one of the most important decisions when launching or running a custom t-shirt shop. The material impacts comfort, durability, print quality, price point, and customer satisfaction. Here’s a breakdown of the three most popular fabric types to help you make informed choices for your product lineup.

100% Cotton: Classic Comfort and Natural Feel

Overview:
100% cotton t-shirts are made entirely from natural cotton fibers. They are a timeless favorite, prized for their softness, breathability, and eco-friendly appeal.

Pros:
– Soft and comfortable against the skin, especially after a few washes.
– Highly breathable, making them ideal for warm weather and active wear.
– Excellent for printing—inks adhere well, resulting in vibrant, crisp designs.
– Biodegradable and sustainable, appealing to environmentally conscious customers.
– Natural feel that many customers prefer over synthetic blends.

Cons:
– Prone to shrinking, especially if not pre-shrunk (look for preshrunk cotton).
– Less durable over time—can wear thin, pill, or stretch out with frequent washing.
– Absorbs moisture easily, which can make the shirt feel heavy when wet.
– Wrinkles more than blended fabrics.

Best For:
Customers seeking a classic, natural-feeling tee; eco-conscious buyers; screen printing and DTG (direct-to-garment) applications; everyday casual wear.

50/50 Blend: The Balanced Middle Ground

Overview:
A 50/50 blend typically combines 50% cotton with 50% polyester. This hybrid fabric offers a balance of comfort and performance, making it a popular choice for custom apparel.

Pros:
– Resists shrinking and wrinkling better than 100% cotton.
– More durable and long-lasting due to polyester’s strength.
– Lightweight and moisture-wicking, keeping wearers drier during activity.
– Affordable to produce and sell, making it great for budget-friendly options.
– Holds shape well over time and multiple washes.

Cons:
– Less breathable than 100% cotton, which may feel warmer in hot climates.
– Can feel slightly synthetic or less soft initially (though modern versions have improved).
– Prone to pilling after repeated use and washing.
– Printing may require adjustments—polyester can affect ink absorption and color vibrancy.

Best For:
Promotional shirts, event tees, budget-conscious customers, and situations where durability and consistent sizing are priorities. Ideal for both screen printing and DTG.

Tri-Blends: Premium Softness and Modern Style

Overview:
Tri-blend fabrics typically combine three fibers—commonly 50% polyester, 25% cotton, and 25% rayon (or modal). This mix creates a luxurious, vintage-soft hand feel with excellent drape.

Pros:
– Exceptionally soft and smooth, often described as “buttery” or “silky.”
– Great drape and stretch, conforming comfortably to the body.
– Vintage aesthetic with a slightly heathered or worn-in look that appeals to fashion-forward customers.
– Resists shrinking better than 100% cotton.
– Lightweight and breathable, combining the best traits of all three fibers.

Cons:
– Higher price point due to more expensive materials and production.
– Less durable than cotton or 50/50 blends—can be more prone to snagging or thinning.
– Requires careful printing techniques—rayon and polyester can react differently to inks.
– May not be ideal for heavy-duty use or high-activity environments.

Best For:
Premium or lifestyle brands, fashion-focused customers, boutique shops, and soft-style prints. Excellent for DTG printing due to its smooth surface.

Choosing the Right Fabric for Your Shop

When deciding which fabrics to offer, consider your target market, price positioning, and intended use:

• Offer variety: Stock all three types to cater to different customer needs—budget, classic, and premium.
• Know your audience: Eco-buyers may prefer 100% cotton; event planners might choose 50/50 for cost and durability; fashion brands may lean into tri-blends.
• Test print quality: Always run print tests on each fabric type to ensure your designs look their best.
• Source quality blanks: Partner with reliable suppliers who offer consistent fabric weights (e.g., 4.5 oz vs. 6.1 oz) and pre-shrunk options.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can build a versatile, high-quality custom t-shirt line that meets diverse customer expectations and stands out in a competitive market.

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

Ordering custom t-shirts in bulk can be a cost-effective way to outfit a team, promote a brand, or sell merchandise. However, to get the best price without sacrificing quality, it pays to understand bulk pricing strategies and how to optimize your artwork. Here’s a comprehensive guide to help you save money and get high-quality results.

Understand Bulk Quantity Breaks

Most custom t-shirt printers offer tiered pricing based on the number of shirts ordered. The more you order, the lower the per-unit cost.

• Know the thresholds: Common bulk breaks occur at 24, 48, 72, 100, and 250 units. Ordering just above a break (e.g., 101 instead of 100) may not offer savings—aim for the next full tier.
• Compare vendors: Prices and break points vary. Request quotes from multiple suppliers to find the best deal.
• Consider future needs: If you anticipate needing more shirts later, ordering a larger quantity now can lower costs and avoid future setup fees.

Choose the Right T-Shirt Type and Brand

Not all shirts are created equal—and pricing varies significantly by fabric, brand, and quality.

• Opt for value-priced blanks: Brands like Gildan, Bella+Canvas, and Hanes offer affordable, high-quality options ideal for bulk orders.
• Stick to one style: Mixing shirt styles or brands can increase costs due to separate setup and printing fees.
• Avoid over-specifying: Unless required, avoid premium fabrics or specialty cuts that drive up prices.

Simplify Your Design to Reduce Printing Costs

Printing complexity directly impacts your total cost. Here’s how to keep your design budget-friendly:

• Limit the number of colors: Each additional ink color increases screen setup and printing time. Stick to 1–3 colors for the best pricing.
• Use fewer print locations: Printing on just the front typically costs less than front and back or sleeve prints.
• Avoid all-over prints: Full-shirt designs require more ink and time, significantly increasing costs.

Prepare Print-Ready Artwork

Submitting high-quality artwork prevents delays and extra fees.

• Use vector files (AI, EPS, SVG): These scale perfectly for screen printing and are preferred by printers.
• Provide high-resolution raster files (300 DPI): If using PNG or JPG, ensure they’re crisp and large enough.
• Outline text and embed fonts: Prevents font issues during production.
• Confirm color modes: Use CMYK or spot colors (Pantone) for accurate printing—avoid RGB for print designs.

Time Your Order Strategically

• Order off-season: Many suppliers offer discounts during slower months (e.g., late winter).
• Avoid rush fees: Plan ahead to skip expedited processing charges.
• Look for promotions: Subscribe to vendor newsletters for seasonal sales or first-order discounts.

Request a Physical Sample

Before committing to a large order, get a sample shirt printed.

• Verify print quality and color accuracy.
• Check fabric feel and fit.
• Avoid costly mistakes due to miscommunication.

Negotiate and Bundle Services

• Ask for discounts on repeat orders.
• Bundle services like design help, packaging, or shipping for a better rate.
• Leverage long-term partnerships with suppliers for ongoing savings.

By understanding bulk pricing, simplifying your design, and preparing professional artwork, you can significantly reduce costs while maintaining great quality for your custom t-shirt shop. Plan wisely, compare options, and build strong relationships with reliable printers to get the best value.