Screen Printing vs. DTG vs. Heat Transfer for Custom T-Shirts: A Comparison Table

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|—————————-|——————————————|——————————————-|——————————————-|
| Best For | Large orders, simple designs | Small orders, detailed/full-color designs | Small runs, quick turnaround, photos |
| Design Complexity | Limited (1-6 colors ideal) | High (full-color, gradients, photos) | High (full-color, photos, intricate art) |
| Durability | Excellent (long-lasting, withstands washes) | Good (may fade after many washes) | Fair to Good (can crack or peel over time)|
| Feel on Fabric | Slightly thick, plasticky (depending on ink) | Soft, breathable (inks absorb into fabric) | Can be stiff or rubbery (especially vinyl)|
| Setup Time/Cost | High (screens required per color) | Low (minimal setup, print directly) | Low (design printed/cut, then applied) |
| Cost Efficiency | Cost-effective for large quantities | More expensive per unit, better for small runs | Low upfront cost, cost rises with volume |
| Fabric Compatibility | Best on 100% cotton; blends possible | Best on 100% cotton; lighter blends work | Works on most fabrics, including polyester|
| Color Accuracy | High (consistent with spot colors) | High (excellent color reproduction) | High (good for complex images) |
| Production Speed | Fast for large batches | Slower (print one at a time) | Moderate (depends on transfer method) |
| Eco-Friendliness | Moderate (plastisol inks less eco-friendly; water-based better) | High (uses water-based inks) | Low to Moderate (vinyl transfers less eco-friendly) |
| Minimum Order Quantity | Recommended 25+ pieces | As low as 1 piece | As low as 1 piece |
| Ideal Use Cases | Bulk orders (events, teams, merch) | Custom one-offs, complex artwork, photos | Rapid prototypes, small batches, polyester garments |

Note: Performance can vary based on equipment, inks, and application techniques.

100% Cotton vs. Tri-Blends vs. Polyester: Your Guide to Choosing Fabrics for Custom T-Shirts

Choosing the right fabric is crucial when creating custom t-shirts—it affects comfort, durability, appearance, and how well your design prints. Here’s a breakdown of the three most common options to help you decide.

100% Cotton

Pros:
– Soft and Breathable: Natural fibers make cotton highly breathable, ideal for everyday wear and warmer climates.
– Comfortable Feel: Offers a classic, soft hand feel that many people prefer.
– Great for Printing: Holds screen printing and direct-to-garment (DTG) ink well, resulting in vibrant, crisp designs.
– Eco-Friendly (to an extent): Biodegradable and renewable, especially if organic cotton is used.

Cons:
– Prone to Shrinking: Can shrink when washed in hot water, especially if not pre-shrunk.
– Less Durable: May wear out faster than synthetic blends, especially after repeated washing.
– Wrinkles Easily: Requires more ironing or careful folding.
– Absorbs Moisture: Holds sweat, which can lead to odor retention and slower drying.

Best For: Casual wear, vintage-style tees, eco-conscious brands, and designs with detailed prints.

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

Pros:
– Super Soft and Drapey: Rayon adds a silky texture and excellent drape, giving a more fitted, modern look.
– Lightweight & Comfortable: Ideal for layering or wearing in mild to warm weather.
– Resists Wrinkling: Holds its shape better than 100% cotton and resists creasing.
– Color-Rich Prints: The smooth surface enhances printed designs, especially with DTG, offering a vintage or worn-in aesthetic.

Cons:
– Less Breathable: Higher synthetic content reduces breathability compared to pure cotton.
– Pilling Over Time: May develop small fabric balls (pills) with frequent wear and washing.
– Heat Sensitivity: Can be damaged by high heat during washing or ironing.
– Not as Eco-Friendly: Contains synthetic fibers derived from petroleum.

Best For: Fashion-forward custom tees, women’s cuts, vintage-style prints, and lifestyle or boutique brands.

100% Polyester

Pros:
– Durable & Long-Lasting: Resistant to shrinking, stretching, and fading—great for performance wear.
– Moisture-Wicking: Pulls sweat away from the skin, ideal for athletic or active use.
– Quick-Drying: Excellent for sportswear, outdoor events, or humid climates.
– Wrinkle-Resistant: Holds its shape and looks crisp after washing.

Cons:
– Less Comfortable for Everyday Wear: Can feel plasticky or trap heat, leading to discomfort in warm conditions.
– Prone to Odor Retention: Polyester fibers can hold onto sweat and bacteria, causing odors over time.
– Static Cling: May generate static, especially in dry environments.
– Printing Challenges: Requires special inks (like sublimation) for best results; standard DTG may not adhere as well.

Best For: Performance apparel, sportswear, promotional event shirts, and sublimation printing on light-colored garments.

How to Choose the Right Fabric

• For Comfort & Casual Wear: Choose 100% cotton or tri-blend for softness and breathability.
• For Active or Sporty Use: Opt for 100% polyester or performance blends with moisture-wicking properties.
• For Premium Look & Vintage Style: Tri-blends offer a luxurious drape and lived-in feel.
• For Eco-Conscious Brands: Prioritize organic cotton or recycled polyester options.
• For Long-Lasting Prints: 100% cotton and tri-blends work best with DTG, while polyester excels with dye-sublimation.

By understanding the strengths and weaknesses of each fabric, you can select the perfect material that aligns with your brand, audience, and design goals.

How to Get the Best Price for Custom T-Shirts (Bulk Discounts & Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. However, to truly get the best price, you need to understand how bulk discounts work and how to prepare your artwork efficiently. Here’s how to save money without sacrificing quality.

Understand Bulk Discount Tiers

Most screen printers and custom apparel companies offer tiered pricing based on quantity. The more shirts you order, the lower the per-unit cost. To maximize savings:

• Order in higher quantity brackets: For example, moving from 50 to 100 shirts often cuts the price per shirt nearly in half.
• Know standard tiers: Common discount levels are 12, 24, 50, 100, 250, and 500+ units. Jumping to the next tier can save you significantly.
• Consolidate orders: If multiple departments or groups need shirts, combine orders to reach a higher discount tier.
• Consider future needs: If you anticipate needing more shirts later, order extra now to lock in a lower rate—just ensure proper storage.

Choose the Right Shirt Style and Brand

The type of t-shirt has a big impact on price:

• Opt for budget-friendly blanks: Basic cotton shirts (e.g., Gildan 5000, Hanes Beefy-T) are cheaper than premium brands (like Bella+Canvas 3001).
• Stick to one style and color: Mixing shirt styles or colors increases setup and printing costs.
• Avoid specialty fabrics: Tri-blend, organic cotton, or performance fabrics cost more—only use them if necessary.

Minimize Print Complexity

The design directly affects pricing—especially with screen printing:

• Use fewer colors: Each color requires a separate screen and setup fee. Stick to 1–3 colors to reduce costs.
• Choose simpler designs: Avoid intricate details or gradients that require advanced (and more expensive) printing methods.
• Limit print locations: Printing on just the front is cheaper than front and back. Avoid sleeves or side prints unless essential.

Prepare Your Artwork Properly

Well-prepared artwork prevents costly delays and reprints:

• Use vector files (AI, EPS, SVG): These scale infinitely and are ideal for screen printing and embroidery.
• Submit high-resolution raster files (300 DPI): If using PNG or JPEG, ensure they’re high resolution and the correct size.
• Outline fonts and convert to curves: This prevents font issues during printing.
• Specify Pantone (PMS) colors: Ensures accurate color matching and avoids guesswork.
• Provide a clear mockup: Helps the printer understand your vision and reduces revision costs.

Get Multiple Quotes

Don’t settle for the first quote:

• Compare at least 3–5 suppliers: Prices vary widely between local screen printers, online vendors (like Custom Ink, Printful, or RushOrderTees), and wholesale decorators.
• Ask about setup fees: Some charge per-color setup fees; others waive them for larger orders. Clarify what’s included.
• Inquire about bundled deals: Some companies offer lower prices when combining t-shirts with hats, hoodies, or other apparel.

Time Your Order Strategically

• Avoid peak seasons: Holidays, back-to-school, and major events can increase demand and prices.
• Order early: Last-minute rush fees can double your costs. Plan ahead for events.
• Look for promotions: Many suppliers offer seasonal discounts, first-time customer deals, or referral bonuses.

By leveraging bulk discounts, simplifying your design, preparing professional artwork, and shopping wisely, you can get high-quality custom t-shirts at the best possible price.