Comparison: Screen Printing, DTG, and Heat Transfer for Custom T-Shirts with Photos

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Best Fabric for Your Custom Photo T-Shirt

When creating a custom t-shirt with a photo, the fabric you choose plays a crucial role in comfort, durability, and—most importantly—how well your image turns out. With options like 100% cotton, 50/50 blends, and tri-blends, it’s essential to understand the differences. Here’s a breakdown to help you make the best choice.

100% Cotton: Classic Comfort with a Natural Feel

Pros:
– Soft and breathable: Ideal for everyday wear, especially in warmer weather.
– Natural fiber: Eco-friendly and biodegradable.
– Great for printing: Provides a smooth, matte surface that works well with standard printing techniques like screen printing or direct-to-garment (DTG).
– Absorbs ink well: Produces rich, vibrant colors—especially effective for high-contrast photos.

Cons:
– Prone to shrinking: May shrink up to 5-7% if not pre-shrunk.
– Less durable: Can wear out faster with frequent washing.
– Wrinkles easily: Requires more care when washing and drying.

Best for: Classic, vintage-style photo shirts, casual wear, and those who prefer a natural, soft feel.

50/50 Blend: The Best of Both Worlds

What it is: A mix of 50% cotton and 50% polyester.

Pros:
– Durable and long-lasting: Resists pilling and fading over time.
– Minimal shrinkage: Holds its shape better than 100% cotton.
– Affordable: Typically budget-friendly without sacrificing quality.
– Good print performance: Polyester helps colors stay bright, while cotton ensures softness.

Cons:
– Slightly less soft: Can feel a bit rougher than 100% cotton.
– Less breathable: May retain heat more, making it less ideal for hot climates.
– Shinier finish: The polyester can give a slight sheen, which may alter photo appearance.

Best for: Active wear, promotional shirts, or when you want a balance of comfort, durability, and print clarity.

Tri-Blend: Softness and Style in One

What it is: A blend of approximately 50% polyester, 25% cotton, and 25% rayon (often modal or viscose).

Pros:
– Ultra-soft and silky: Offers a luxurious drape and smooth feel—like a worn-in vintage tee.
– Excellent drape: Flatters the body and reduces clinging.
– Color vibrancy: Rayon enhances color depth and gives a vintage, slightly faded look that works beautifully with photo prints.
– Resists shrinking and fading: Thanks to the polyester content.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Less durable under stress: Can be prone to snagging or pilling with rough use.
– Delicate care: May require washing in cold water and air drying to maintain quality.

Best for: Fashion-forward custom photo tees, gifts, or anyone seeking a premium, soft, vintage-inspired look.

Final Tips for Choosing the Right Fabric

• For vibrant, detailed photos: Choose 100% cotton or 50/50 blend for crisp, clear results.
• For a soft, vintage aesthetic: Tri-blend gives that sought-after retro feel.
• For active or frequent wear: 50/50 blend offers the best durability.
• For comfort and breathability: 100% cotton wins in warm weather.

Ultimately, your choice depends on how you plan to wear and care for your custom photo t-shirt. Consider the photo style, intended use, and personal preferences to find the perfect fabric match.

How to Get the Best Price for Custom T-Shirts with Photos (Bulk Quantity Breaks & Artwork Tips)

Ordering custom t-shirts with photos in bulk can be a cost-effective way to promote your brand, event, or team. By understanding quantity discounts and optimizing your artwork, you can significantly reduce costs without sacrificing quality. Here’s how:

Leverage Bulk Quantity Breaks

Most custom apparel printers offer tiered pricing based on order size. The more you order, the lower the per-unit cost. Here’s how to take full advantage:

• Know the Break Points: Common quantity breaks are at 25, 50, 100, and 250 units. For example, the price per shirt might drop noticeably at 100 units. Always ask for a pricing chart to identify the most cost-effective tier.

• Consolidate Orders: If you’re unsure about future needs, consider ordering slightly more now to hit a lower price tier. Extra shirts can be stored for later use and still cost less than a future small order.

• Standardize Designs: If ordering for different groups (e.g., departments or teams), use the same base design with minor variations to keep print runs large and costs low.

• Choose One Shirt Style and Color: Ordering multiple colors or styles splits your quantity and may prevent you from reaching a bulk discount. Stick to one color and cut (e.g., Gildan Softstyle in black) for maximum savings.

Optimize Your Artwork for Cost and Quality

The way you prepare your photo artwork directly impacts printing cost and final appearance.

• Use High-Resolution Images: For photo printing, aim for at least 300 DPI at the intended print size. Low-res images will look blurry when enlarged.

• Simplify When Possible: Full-color photo prints (especially on dark shirts) often use DTG (Direct-to-Garment) printing, which can be more expensive than screen printing. If your photo has large areas of solid color or can be converted to a graphic-style design, consider vectorization to reduce ink usage and cost.

• Choose the Right Print Method:

• DTG (Direct-to-Garment): Best for detailed photos and small runs. Cost-effective for full-color designs, but more expensive per shirt than screen printing.
• Dye Sublimation: Ideal for all-over prints but requires polyester fabric.

• Screen Printing with Simulated Process: Can mimic photo quality at lower cost for large runs, but setup fees apply.

• Reduce Print Area: Smaller prints use less ink and time. Consider a chest-sized print instead of a full front or back.

• Use Vector or Print-Ready Files: Submit artwork in vector (AI, EPS, SVG) or high-res PNG/PDF formats. Avoid blurry JPGs from social media.

• Work with the Printer’s Template: Most companies provide design templates. Use them to ensure proper placement and sizing.

Additional Cost-Saving Tips

• Compare Multiple Vendors: Get quotes from several reputable printers (e.g., Custom Ink, Printful, RushOrderTees). Look beyond price—check reviews for print durability and customer service.

• Watch for Promotions: Many sites offer seasonal discounts, first-order deals, or free shipping on bulk orders.

• Avoid Rush Fees: Plan ahead. Standard production times are cheaper than rush processing.

• Bundle with Other Items: Some suppliers offer discounts when you order hoodies, hats, or tote bags along with your shirts.

By combining smart bulk ordering with professional artwork preparation, you can achieve vibrant, high-quality photo t-shirts at the best possible price. Always request a sample before placing a large order to verify print quality and fit.