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

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

When ordering custom screen-printed t-shirts, one of the most important decisions you’ll make is choosing the right fabric. The material affects not only the comfort and durability of the shirt, but also how well your design prints and holds up over time. Here’s a breakdown of the three most popular fabric options: 100% cotton, 50/50 blends, and tri-blends.

100% Cotton

Pros:
– Soft and breathable: Cotton is a natural fiber that feels soft against the skin and allows good airflow, making it ideal for warm weather and everyday wear.
– Excellent ink absorption: Cotton holds screen-printed ink well, resulting in vibrant, crisp prints with strong opacity.
– Classic feel: Offers that traditional t-shirt hand-feel that many customers prefer.

Cons:
– Prone to shrinking: 100% cotton can shrink in the dryer, especially if not pre-shrunk during manufacturing.
– Less durable: Over time, cotton may wear out faster, particularly with frequent washing.
– Wrinkles easily: Cotton tends to wrinkle more than synthetic blends.

Best for: Events, promotional giveaways, and retail apparel where comfort and print quality are top priorities.

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

Pros:
– Durable and long-lasting: The polyester adds strength, helping the shirt resist shrinking and wear over time.
– Minimal shrinkage: Blended fibers are more stable in the wash and dryer.
– Lightweight and affordable: A great middle-ground option that balances comfort and cost.
– Good print performance: Works well with screen printing, though ink may sit slightly more on the surface than with 100% cotton.

Cons:
– Less breathable: Polyester doesn’t breathe as well as cotton, which can make the shirt feel warmer.
– Can feel less soft: Some people find 50/50 blends slightly less comfortable than pure cotton, especially in hot weather.

Best for: School spirit wear, employee uniforms, and events where durability and value are key.

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

Pros:
– Luxurious softness: Known for a smooth, vintage-like feel that’s exceptionally soft and drapes well.
– Excellent drape and comfort: Great for fashion-forward or fitted styles.
– Reduced shrinkage: The blend resists shrinking better than 100% cotton.
– Unique aesthetic: Offers a heathered or marled appearance that looks stylish even without printing.

Cons:
– More delicate: Tri-blends can be more prone to pilling and may not hold up as well to heavy use or frequent washing.
– Printing considerations: The rayon content can react differently to heat during curing, so proper screen printing techniques are essential.
– Higher cost: Typically more expensive than cotton or 50/50 options.

Best for: Premium merchandise, boutique apparel, and fashion-oriented designs where softness and style matter.

Final Tips for Choosing the Right Fabric

• Consider your audience: Are they looking for comfort, durability, or style?
• Think about usage: Will the shirts be worn daily, for special events, or as keepsakes?
• Test print if possible: Always run a test print on your chosen fabric to ensure color vibrancy and ink adhesion.
• Check garment care: Inform customers how to care for their shirts to preserve both fabric and print.

By understanding the differences between 100% cotton, 50/50 blends, and tri-blends, you can make a confident choice that ensures your custom screen-printed t-shirts look great, feel comfortable, and stand the test of time.

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

Getting high-quality custom t-shirts at the best price involves smart planning, especially when ordering in bulk. By leveraging quantity breaks, optimizing your artwork, and choosing the right supplier, you can save significantly without sacrificing quality. Here’s how:

Take Advantage of Bulk Quantity Breaks

Screen printing companies typically offer tiered pricing based on order volume—commonly known as “quantity breaks.” The more shirts you order, the lower the per-unit cost.

• Order in Larger Quantities: Prices often drop at benchmarks like 50, 100, 250, or 500+ units. For example, 100 shirts might cost $8 each, but 250 could drop to $5 each.
• Consolidate Designs: If you need multiple designs, consider standardizing colors and print locations to qualify for bulk pricing across designs.
• Plan Ahead: Group orders with friends, teams, or events to maximize quantity and reduce individual costs.

Optimize Your Artwork for Lower Printing Costs

The complexity of your design directly impacts printing time, materials, and cost. Simplify your artwork to save money.

• Limit the Number of Colors: Each additional ink color requires a separate screen and setup. Stick to 1–3 colors for the best pricing.
• Use Vector Art: Supply clean, vector-based artwork (e.g., AI, EPS, or SVG) to avoid extra fees for file conversion or redrawing.
• Avoid Halftones and Gradients: These require special screens and increase setup time. Solid fills are cheaper and faster to print.
• Simplify the Design: Reduce fine details and small text that may require high-precision screens or risk lower print quality.

Choose the Right Supplier and Materials

Not all printers are created equal—research and compare to find the best value.

• Compare Quotes: Get estimates from multiple screen printing vendors. Look beyond price—consider turnaround time, minimums, and customer reviews.
• Select Affordable, Durable Garments: Basic cotton blanks (like Gildan or Hanes) are cheaper than premium or specialty fabrics and work well for most screen printing needs.
• Print Location Matters: Single-location prints (e.g., front only) are less expensive than multi-location (front and back, sleeves, etc.).

Minimize Setup Fees

Screen printing involves setup costs for each design and color. Reduce these fees by:

• Reusing Screens: If you plan repeat orders, ask if your printer can store screens for future use at no extra charge.
• Combining Orders: Avoid placing multiple small orders; instead, combine them into one larger run.
• Avoiding Rush Fees: Plan ahead and allow standard production times to avoid costly expedited processing.

By following these tips—maximizing bulk discounts, simplifying artwork, and choosing the right supplier—you can achieve professional-quality custom t-shirts at the most competitive price.