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

100% Cotton vs. 50/50 Blend vs. Tri-blends: Choosing the Best Fabric for Custom T-Shirt Transfers

Selecting the right fabric is crucial for achieving professional, durable custom t-shirt transfers. Not all materials react the same way to heat, ink adhesion, or washing. Here’s a breakdown of the three most common fabric types—100% cotton, 50/50 cotton-polyester blend, and tri-blends—to help you choose the best option for your transfer project.

100% Cotton

Pros:
– Excellent Ink Adhesion: Cotton fibers absorb ink well, making it ideal for screen printing and certain types of heat transfers, especially plastisol-based or water-based inks.
– Heat Tolerance: Cotton can withstand high heat (typically up to 400°F), which is essential for most heat press transfers.
– Soft and Breathable: Offers a classic, comfortable feel preferred for everyday wear.
– Eco-Friendly Option: Natural fiber, biodegradable, and often available in organic varieties.

Cons:
– Shrinkage: Prone to shrinking, especially if not pre-shrunk. Always pre-wash if shrinkage is a concern.
– Less Durable Over Time: May wear out faster than blends, especially after repeated washing.
– Wrinkling: More likely to wrinkle compared to synthetic blends.

Best For: Traditional screen-printed transfers, cold peel or hot peel heat transfers, and designs with bold colors. Ideal for vintage-style tees and eco-conscious customers.

50/50 Cotton-Polyester Blend

Pros:
– Durability: Polyester adds strength, reducing wear and tear and minimizing shrinkage.
– Shape Retention: Holds its form better over time and resists wrinkling.
– Faster Drying: Less absorbent than cotton, so it dries quicker.
– Cost-Effective: Often more affordable than 100% cotton or tri-blends.

Cons:
– Heat Sensitivity: Polyester can scorch or melt under high heat (typically above 320°F), so lower temperature settings are required when applying transfers.
– Less Absorbent: May not hold certain inks as well as cotton, potentially leading to a slightly stiffer feel.
– Slight Shiny Appearance: Can give transfers a different finish than on cotton.

Best For: High-volume orders, athletic or casual wear, and environments where durability is key. Use low-temperature transfer papers or specialty inks (like those designed for polyester blends).

Tri-blends (Typically Cotton, Polyester, Rayon)

Pros:
– Luxurious Feel: Soft, lightweight, and drapey with a vintage, worn-in look.
– Reduced Shrinkage: The blend resists shrinking better than 100% cotton.
– Excellent Drape: Ideal for fitted or fashion-forward styles.
– Color Vibrancy: Rayon enhances color absorption, often resulting in rich, vintage-style prints.

Cons:
– Heat Sensitivity: Rayon and polyester components are sensitive to high heat. Use a heat press at lower temperatures (around 270–300°F) and shorter durations.
– Fragility: More delicate than 100% cotton or 50/50 blends; can be prone to pilling or snagging.
– Higher Cost: Typically more expensive due to fabric composition and manufacturing.

Best For: Fashion tees, boutique apparel, and soft hand-feel transfers like sublimation (on high-polyester tri-blends) or specialty heat transfers. Ideal for vintage-inspired designs and women’s or fitted cuts.

Final Tips for Success

• Always Test First: Perform a test press on a fabric swatch to determine optimal time, temperature, and pressure.
• Use the Right Transfer Type: Match your transfer method (inkjet, laser, sublimation, screen print) to the fabric. For example, sublimation works best on high-polyester fabrics.
• Pre-Wash if Needed: Especially for 100% cotton, pre-washing removes sizing and reduces shrinkage.
• Follow Care Instructions: Recommend cold wash, inside-out, and low tumble dry to extend the life of both the garment and the transfer.

By understanding the characteristics of each fabric type, you can ensure your custom t-shirt transfers look great, last longer, and meet your customers’ expectations.

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

Getting high-quality custom t-shirt transfers at the best price is possible with smart planning and strategic ordering. Whether you’re designing for a business, event, or organization, these tips will help you save money—especially when ordering in bulk—while ensuring professional results.

Leverage Bulk Quantity Breaks

Most print providers offer significant discounts when you order in larger quantities. Here’s how to maximize these savings:

• Order in Larger Quantities: Prices per transfer drop substantially at volume thresholds (e.g., 50, 100, 250, 500+ units). Always ask for a pricing breakdown by quantity tier.
• Consolidate Designs: If you have multiple designs, consider standardizing colors or layouts so you can combine quantities under one design to reach bulk pricing faster.
• Plan Ahead: Forecast your needs for events, promotions, or inventory cycles. Ordering ahead allows you to combine future orders into one large batch.
• Compare Vendors: Not all companies offer the same bulk discounts. Get quotes from multiple suppliers and ask about volume pricing schedules.

Optimize Your Artwork for Lower Costs

Artwork quality and preparation can directly impact production costs and print quality. Follow these tips to avoid extra fees and reprints:

• Use High-Resolution Files: Supply artwork at 300 DPI in vector formats (e.g., .AI, .EPS, .SVG) or high-res PNG/PDF. This prevents upscaling fees and ensures crisp prints.
• Simplify Designs: Fewer colors and simpler graphics reduce printing complexity and cost—especially with screen printing or multi-color transfers.
• Stick to Standard Sizes: Avoid oversized or custom-shaped transfers unless necessary. Standard sizes are cheaper to produce and apply.
• Limit Color Count: Each additional color may increase setup and printing costs. Opt for 1–3 color designs when possible.
• Provide Proper Color Matching: Use Pantone (PMS) or CMYK values to avoid color correction fees and ensure consistency across bulk orders.

Additional Cost-Saving Tips

• Choose the Right Transfer Type: Dye sublimation, inkjet, and laser transfers vary in price and durability. Match the transfer type to your fabric and usage needs to avoid overspending.
• Avoid Rush Fees: Standard production times are cheaper. Schedule orders in advance to skip expedited processing charges.
• Request Samples First: Order a sample transfer to test quality and sizing before committing to a large batch.
• Negotiate with Suppliers: For very large orders, don’t hesitate to negotiate pricing, especially with repeat business or referrals.

By combining bulk ordering strategies with professional, print-ready artwork, you’ll get the best value and quality for your custom t-shirt transfers—without sacrificing your budget.