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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing Fabrics for Custom T-Shirts at the Mall

When you’re shopping at the mall for custom t-shirts—whether for a group event, personal style, or promotional giveaways—the fabric choice plays a huge role in comfort, durability, and overall look. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends can help you make the best decision for your needs. Here’s a breakdown of each fabric type to guide your choice.

100% Cotton: Classic Softness and Breathability

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear.
– Natural feel: Offers a traditional, comfortable texture against the skin.
– Great for printing: Holds vibrant screen prints and designs well, especially with water-based inks.

Cons:
– Prone to shrinking: May shrink after washing, especially if not pre-shrunk.
– Less durable: Can wear out faster with frequent washing and heavy use.
– Wrinkles easily: Requires ironing or steaming for a crisp look.

Best for: Casual wear, vintage-style tees, eco-conscious buyers, and custom designs that prioritize softness and natural fibers.

50/50 Blend: The Balanced Middle Ground

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

Pros:
– Durable and resistant to wear: Polyester adds strength and helps the shirt hold its shape.
– Less shrinkage: More stable in the wash than 100% cotton.
– Affordable: Often priced lower than tri-blends and some premium cotton options.

Cons:
– Slightly less soft: Can feel a bit rougher than pure cotton, though modern versions have improved.
– Less breathable: Polyester doesn’t breathe as well, which may make it feel warmer.
– Can pill over time: Especially with frequent friction or washing.

Best for: Budget-friendly bulk orders (like events or staff uniforms), active use, and environments where durability matters more than luxury feel.

Tri-Blend: Premium Comfort with a Vintage Vibe

What it is: Typically a mix of 50% polyester, 25% cotton, and 25% rayon (sometimes viscose).

Pros:
– Ultra-soft and smooth: Feels buttery and drapes well—often compared to a vintage tee.
– Great drape and fit: Flatters the body and resists clinging.
– Resists shrinking and fading: Polyester content enhances longevity.

Cons:
– Higher cost: Usually more expensive than 100% cotton or 50/50 blends.
– Less eco-friendly: Contains synthetic fibers; rayon production can be chemically intensive.
– May be too delicate: Not ideal for heavy-duty use or intense screen printing with thick inks.

Best for: Fashion-forward custom tees, boutique branding, gifts, or when you want a luxurious, soft hand-feel with a slightly elevated look.

Final Tips for Choosing at the Mall

• Feel the fabric: Always touch the shirts in person—comfort is personal.
• Check the tag: Look for exact fabric percentages and care instructions.
• Consider the purpose: Is it for lounging, work, or a special event? Match fabric to function.
• Think about printing method: Some fabrics work better with certain inks or printing styles (e.g., DTG vs. screen printing).

By understanding the key differences between 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the perfect fabric for your custom t-shirts—ensuring comfort, style, and lasting quality.

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

Ordering custom T-shirts in bulk from a mall-based print shop can be affordable—if you know how to negotiate and prepare. Follow these strategies to save money while getting high-quality results.

Leverage Bulk Quantity Breaks for Lower Prices

Most custom apparel shops offer tiered pricing based on order size. The more shirts you buy, the lower the price per unit. Here’s how to maximize savings:

• Ask About Volume Discounts: Inquire about specific pricing tiers (e.g., 25, 50, 100+ units). Often, jumping to the next tier (like 50 instead of 40) costs only slightly more but reduces the per-shirt price significantly.
• Consolidate Orders: Team up with colleagues, clubs, or friends to reach higher quantity brackets. Larger orders qualify for better bulk rates.
• Choose Uniform Sizes and Colors: Ordering in a single color and minimizing size variations streamlines production and reduces costs.
• Select Simpler Garments: Basic cotton T-shirts are cheaper than performance or designer fabrics. Stick with budget-friendly blanks unless quality is a priority.

Optimize Your Artwork to Reduce Printing Costs

Design choices directly impact pricing. Smart artwork preparation lowers setup and print fees.

• Simplify Your Design: Fewer colors mean lower screen or transfer costs. Stick to 1–3 colors when possible—each additional color increases setup time and expense.
• Use Vector Files: Provide artwork in vector format (AI, EPS, or SVG). High-resolution PNGs (300 DPI) are acceptable, but vectors ensure crisp prints and avoid re-drafting fees.
• Avoid Full-Color or Photo Prints: These often require expensive printing methods like DTG (direct-to-garment). Use screen printing for bold, limited-color designs to save money.
• Confirm Print Area and Placement: Smaller prints (e.g., left chest) cost less than large back designs. Standard placements are cheaper than custom positioning.
• Get a Physical Proof: Pay for a sample print if needed—this avoids costly reprints due to color or sizing errors.

By combining smart bulk ordering with print-friendly artwork, you can significantly reduce your cost per shirt—without sacrificing quality. Always get quotes from multiple mall vendors and negotiate based on competition to secure the best deal.