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

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

When creating custom t-shirts, the fabric you choose plays a crucial role in comfort, durability, appearance, and how well your designs print. The three most popular options—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits. Understanding their differences will help you select the best material for your project.

100% Cotton

Pros:
– Soft and Breathable: Natural fibers allow air circulation, making cotton ideal for warm weather and everyday wear.
– Comfortable Feel: Offers a classic, familiar softness that many people prefer.
– Great for Printing: Absorbs ink well, especially with screen printing, resulting in vibrant and crisp designs.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.

Cons:
– Prone to Shrinking: Can shrink if not pre-shrunk or washed improperly.
– Less Durable: More likely to wear out, pill, or lose shape over time with frequent washing.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: Holds sweat and moisture, making it less ideal for active wear.

Best For: Casual wear, promotional giveaways, retail apparel, and customers who prioritize softness and natural fibers.

50/50 Blend (50% Cotton / 50% Polyester)

Pros:
– Balanced Performance: Combines the comfort of cotton with the durability of polyester.
– Resists Shrinking and Wrinkling: Holds its shape better than 100% cotton and requires less maintenance.
– Affordable: Typically priced between 100% cotton and tri-blends.
– Good Printability: Works well with screen printing and direct-to-garment (DTG) methods.

Cons:
– Slightly Less Soft: Can feel a bit rougher than 100% cotton, though newer blends have improved comfort.
– Less Breathable: Polyester reduces airflow compared to pure cotton.
– May Pill Over Time: Friction can cause small fiber balls to form on the surface.

Best For: Active environments, school events, sports teams, or when durability and cost-efficiency are priorities.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon)

Pros:
– Ultra-Soft and Lightweight: Offers a luxurious, vintage-style feel with excellent drape.
– Excellent Drape and Fit: Flatters the body and moves naturally with the wearer.
– Reduced Shrinkage: More stable than 100% cotton due to synthetic fibers.
– Slightly Moisture-Wicking: Polyester helps pull moisture away from the skin.

Cons:
– Higher Price Point: More expensive due to the blend complexity and rayon content.
– Less Durable: Softer fabric may wear faster with heavy use or frequent washing.
– Special Care Required: Often needs gentle washing and low-heat drying to maintain quality.
– Printing Considerations: Requires precise settings for DTG printing; may not be ideal for all screen print inks.

Best For: Fashion-forward apparel, boutique brands, gift items, and customers seeking a premium, soft hand-feel.

Choosing the Right Fabric for Your Needs

• Prioritize Comfort and Natural Feel? Go with 100% Cotton.
• Need Durability and Budget-Friendly Options? Choose a 50/50 Blend.
• Want a Premium, Soft, and Stylish Look? Opt for a Tri-Blend.

Consider your audience, usage, care expectations, and design goals when making your decision. Testing samples of each fabric can also help you and your customers experience the differences firsthand.

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

Getting high-quality custom t-shirts at the best possible price requires smart planning, especially when ordering in bulk. By leveraging quantity breaks and optimizing your artwork, you can significantly reduce costs without sacrificing quality. Here’s how:

Leverage Bulk Quantity Breaks

Most custom t-shirt printing companies offer tiered pricing based on order volume. Understanding and maximizing these quantity breaks can save you hundreds—or even thousands—on large orders.

• Order in Larger Quantities: Prices per shirt drop dramatically at key thresholds (e.g., 50, 100, 250, 500+ units). Always aim for the next pricing tier if your budget allows.
• Consolidate Orders: If multiple teams, events, or departments need shirts, combine orders to hit higher quantity tiers.
• Choose Standard Sizes and Colors: Opting for common t-shirt colors (like black, white, or navy) and standard sizes reduces material costs and speeds up production.
• Stick to One Design: Printing the same design across all shirts reduces setup and labor costs. Avoid multiple designs unless absolutely necessary.

Optimize Your Artwork for Lower Printing Costs

Your design directly impacts printing complexity and cost. Simple, well-prepared artwork saves money and ensures a cleaner final product.

• Use Vector Files (AI, EPS, SVG): High-resolution vector artwork scales perfectly and is preferred by printers. Avoid low-res PNGs or JPEGs.
• Limit Print Colors: Each additional color increases screen setup and printing time. Stick to 1–3 colors for the lowest cost, especially with screen printing.
• Simplify the Design: Minimalist designs with fewer details require less ink and shorter print runs. This reduces both cost and production time.
• Choose the Right Placement: Printing on one location (e.g., chest or back center) is cheaper than multiple print areas (e.g., front and sleeves).
• Confirm Print Size: Provide exact dimensions. Oversized prints use more ink and may incur extra charges.

Additional Cost-Saving Tips

• Compare Multiple Suppliers: Get quotes from at least 3–5 reputable custom t-shirt companies. Look for those offering free samples or proofs.
• Avoid Rush Fees: Plan ahead. Standard production times are cheaper than rush orders.
• Use Budget-Friendly Materials: 100% cotton or cotton blends are cost-effective and widely available. Avoid specialty fabrics unless required.
• Request a Free Mockup: Most suppliers offer digital proofs. Use them to catch errors early and avoid costly reprints.

By combining smart bulk ordering with efficient artwork practices, you’ll get premium custom t-shirts at the most competitive price. Always communicate clearly with your printer and plan early to maximize savings.