Screen Printing vs. DTG vs. Heat Transfer: Custom T-Shirt Printing Comparison

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|—————————-|———————————————-|———————————————-|———————————————–|
| Best For | Large orders, solid colors, simple designs | Small orders, detailed/photographic designs | Small batches, on-demand printing, DIY use |
| Setup Time & Cost | High (requires screens per color) | Low (minimal setup) | Low (design prep only) |
| Print Quality | Crisp, opaque, vibrant (on dark garments) | High detail, photo-realistic, soft feel | Can vary; may feel plasticky or stiff |
| Durability | Very durable (lasts many washes) | Good (may fade over time, especially on darks)| Fair to poor (peeling/cracking after washes) |
| Color Capability | Limited by number of screens (spot colors) | Full color (unlimited gradients & shades) | Full color (via inkjet/laser sublimation) |
| Fabric Compatibility | Works on cotton, polyester, blends | Best on 100% cotton; less effective on synthetics | Works on cotton, polyester, blends (varies by method) |
| Cost Efficiency | Cost-effective for large runs | Cost-effective for small runs (1–50 units) | Moderate; higher per-unit cost at scale |
| Production Speed | Fast once setup (high volume) | Slower per unit (ideal for small batches) | Fast for single items; slower for bulk |
| Eco-Friendliness | Moderate (ink & water waste in cleanup) | Higher (water-based inks, lower waste) | Varies (some use solvent inks or vinyl waste) |
| Design Flexibility | Low (design changes require new screens) | High (easy design changes) | High (quick digital changes) |
| Feel on Fabric | Thick, can be heavy (plastisol) | Soft, breathable (inks soak into fabric) | Can be stiff or rubbery (especially vinyl) |
| Ideal Use Cases | Band tees, event shirts, bulk promotional wear | Art prints, complex graphics, custom one-offs | Retail customization, names/numbers, DIY projects |

Summary:
– Screen Printing excels in durability and cost for large, simple-color runs.
– DTG is ideal for intricate, colorful designs on cotton in small quantities.
– Heat Transfer offers quick turnaround and design flexibility but may lack longevity.

Choose based on order size, design complexity, fabric type, and desired feel and durability.

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

When designing custom t-shirts, the fabric you choose plays a crucial role in comfort, appearance, durability, and print quality. Understanding the differences between 100% cotton, tri-blends, and polyester helps you make the best choice for your needs. Here’s a detailed comparison to guide your decision.

100% Cotton

Pros:
– Soft and Breathable: Cotton is naturally soft, breathable, and ideal for everyday wear, especially in warm climates.
– Comfortable Feel: Offers a classic, familiar feel that many people prefer.
– Excellent for Printing: Absorbs ink well, making it ideal for vibrant screen printing and detailed designs.
– Eco-Friendly Option: Biodegradable and often available in organic forms.

Cons:
– Prone to Shrinking: Can shrink if not pre-shrunk or washed improperly.
– Less Durable: May wear out faster and pill over time with frequent washing.
– Not Moisture-Wicking: Absorbs sweat but doesn’t dry quickly, which can feel damp during physical activity.

Best For: Casual wear, promotional shirts, events in moderate climates, and designs requiring rich ink coverage.

Tri-Blends (Typically Cotton, Polyester, Rayon)

Pros:
– Ultra-Soft Hand Feel: Blends often feel buttery soft with a slightly heathered appearance.
– Lightweight and Drapes Well: Offers a more fitted, modern look with excellent drape.
– Reduced Shrinkage: More stable than 100% cotton and retains shape better.
– Good Print Surface: Works well with soft-hand ink and water-based prints for a vintage look.

Cons:
– Less Breathable: May not be as breathable as pure cotton due to synthetic content.
– Can Be Delicate: Some tri-blends are more prone to snagging or pilling.
– Higher Price Point: Typically more expensive than 100% cotton or polyester.

Best For: Fashion-forward tees, women’s cuts, vintage-style designs, and garments where softness and drape are priorities.

Polyester

Pros:
– Durable and Wrinkle-Resistant: Holds up well to repeated washing and maintains shape.
– Moisture-Wicking: Draws sweat away from the body, making it ideal for activewear.
– Quick-Drying: Excellent for sports, outdoor events, or humid environments.
– Color Retention: Prints stay vibrant longer, especially with dye-sublimation techniques.

Cons:
– Can Feel Synthetic: Some people find polyester less comfortable due to reduced breathability.
– Prone to Odor Retention: May hold onto odors more than natural fibers without antimicrobial treatment.
– Not Eco-Friendly: Derived from petroleum and not biodegradable (though recycled polyester is a greener option).

Best For: Performance wear, athletic teams, outdoor events, promotional giveaways in hot climates, and all-over prints using dye-sublimation.

Choosing the Right Fabric

Consider these key factors when deciding:
– Intended Use: Daily casual wear favors cotton or tri-blends; active use calls for polyester.
– Climate: Hot and humid? Go for breathable cotton or moisture-wicking polyester.
– Design Type: Detailed prints work best on cotton; all-over prints shine on polyester.
– Budget: Cotton and polyester are generally more affordable than tri-blends.
– Sustainability Goals: Organic cotton and recycled polyester offer eco-conscious alternatives.

By matching the fabric to your audience, purpose, and design, you’ll create custom t-shirts that look great, wear comfortably, and deliver lasting satisfaction.

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, team, or event. To maximize your savings and ensure high-quality results, follow these key strategies focusing on bulk discounts and artwork preparation.

Leverage Bulk Discounts Effectively

One of the most significant ways to reduce the per-unit cost of custom t-shirts is by taking full advantage of bulk pricing. Here’s how:

• Order Larger Quantities: Most printers offer tiered pricing—larger orders result in lower prices per shirt. For example, ordering 100 shirts may cost $8 each, while 500 shirts could drop to $5 each. Always ask for a complete price breakdown based on volume.

• Consolidate Designs: If you need multiple designs, consider standardizing elements like colors or layout across shirts. Fewer unique designs mean lower setup and printing fees.

• Choose Simpler Printing Methods: Screen printing is typically more cost-effective for large orders with limited colors, while direct-to-garment (DTG) is better for small batches or full-color designs. Opting for screen printing with fewer ink colors can significantly reduce costs.

• Select Budget-Friendly Apparel: Basic cotton or cotton-polyester blends are usually cheaper than premium or specialty fabrics (e.g., organic cotton or performance wear). Choose a reliable but economical blank shirt.

• Compare Multiple Vendors: Get quotes from several suppliers. Look beyond the initial price—consider shipping, setup fees, and turnaround time. Some vendors offer price-matching or first-time customer discounts.

Prepare Artwork to Minimize Costs and Delays

High-quality, well-prepared artwork ensures clean printing and prevents costly revisions or reprints. Follow these tips:

• Use Vector Files When Possible: Provide artwork in vector formats like .AI, .EPS, or .SVG. These scale infinitely without losing quality, making them ideal for printing. Avoid low-resolution .JPG or .PNG files.

• Simplify Your Design: Fewer colors mean lower screen printing costs. Aim for 1–3 ink colors. Convert complex designs into simpler versions that maintain impact but reduce production expenses.

• Set Proper Bleed and Safe Zones: Include a 1/8-inch bleed (extra image area) and keep critical text and logos within the safe zone to avoid being cut off during cutting.

• Specify Colors Accurately: Use Pantone (PMS) color codes for precise color matching. If you’re open to approximation, it may save on custom ink mixing.

• Confirm File Resolution: For non-vector artwork (e.g., DTG printing), ensure a resolution of at least 300 DPI at actual print size to avoid blurry results.

• Get a Digital Proof: Always request a virtual proof before production begins. This helps catch sizing, placement, or color issues early—avoiding costly mistakes.

By combining smart bulk ordering practices with professional artwork preparation, you can achieve high-quality custom t-shirts at the most competitive price. Plan ahead, communicate clearly with your printer, and you’ll get maximum value from your order.