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

100% Cotton vs. 50/50 Blend vs. Tri-blend: Choosing the Right Fabric for Custom Printed T-Shirts

When designing custom printed t-shirts, selecting the right fabric is crucial—it affects comfort, durability, print quality, and overall customer satisfaction. Here’s a breakdown of the three most popular fabric options to help you make an informed choice.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, comfortable feel ideal for everyday wear.
– Eco-Friendly: Biodegradable and made from a renewable resource.
– Great Ink Absorption: Absorbs water-based and plastisol inks well, resulting in vibrant prints.
– Classic Feel: Preferred by those who appreciate the traditional cotton t-shirt experience.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk or washed in hot water.
– Less Durable Over Time: Can wear out, pill, or lose shape faster than blended fabrics.
– Less Stretch: Minimal elasticity, which may not suit performance or tight-fitting designs.

Best For: Casual wear, vintage-style prints, eco-conscious brands, and customers who value natural fibers.

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

Pros:
– Balanced Performance: Combines the softness of cotton with the durability and wrinkle resistance of polyester.
– Reduced Shrinkage: More stable than 100% cotton—less likely to shrink in the wash.
– Affordable: Often more budget-friendly than tri-blends, making it ideal for bulk orders.
– Good Print Surface: Works well with most printing techniques, including screen printing and DTG.

Cons:
– Less Breathable: Polyester content can trap heat, making it less ideal for hot climates.
– Slight Sheen: May have a subtle synthetic look compared to 100% cotton.
– Pilling Over Time: Can develop small fabric balls with repeated washing.

Best For: Promotional apparel, events, workwear, and cost-effective bulk orders where durability and value are priorities.

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

Pros:
– Luxuriously Soft: Feels buttery smooth and drapes beautifully—often compared to vintage tees.
– Excellent Drape and Stretch: Comfortable fit with a slightly fitted, modern silhouette.
– Fade-Resistant: Polyester content helps maintain print vibrancy over time.
– Minimal Shrinkage: Very stable in the wash when cared for properly.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Delicate Fabric: Can be prone to snagging or pilling if exposed to rough surfaces.
– Special Care Required: Best washed inside out in cold water and air-dried to maintain quality.

Best For: Premium apparel, fashion-forward designs, boutique brands, and customers seeking a soft, vintage-inspired look.

Final Tips for Choosing

• Consider Your Audience: Are they looking for comfort, durability, or a high-end feel?
• Match Fabric to Print Type: DTG printing shines on cotton and tri-blends, while screen printing works well on all.
• Think About Use Case: Active wear? Go for blends. Eco-friendly merch? Choose 100% organic cotton.
• Order Samples: Always test print and feel fabric swatches before placing a large order.

By aligning your fabric choice with your brand, design, and customer expectations, you’ll ensure your custom t-shirts look great, feel comfortable, and stand the test of time.

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

Ordering custom t-shirts in bulk can be cost-effective, but maximizing savings requires strategy. Understanding quantity breaks and preparing your artwork properly are two of the most powerful ways to reduce costs. Here’s how to get the best price on your custom t-shirt order.

Understand Bulk Quantity Breaks

Most print shops offer tiered pricing—larger orders cost less per shirt. To get the best deal:

• Know the Break Points: Common quantity tiers are 25, 50, 100, 250, and 500+. Prices often drop significantly at these thresholds. For example, 49 shirts might cost $12 each, while 50 cost $8 each.
• Order Just Over the Break: If you need 45 shirts, ordering 50 could save you money overall—even if you have a few extras.
• Compare Vendors: Different suppliers have different break points and pricing. Get quotes from multiple companies (e.g., Printful, Custom Ink, SanMar, local screen printers) to find the best per-unit rate.
• Consider Group Orders: If you’re part of a team, club, or event, combine orders to hit higher quantity tiers and share savings.

Simplify Your Design to Reduce Printing Costs

The complexity of your artwork directly impacts pricing—especially with screen printing.

• Limit Print Colors: Each additional color requires a separate screen and setup fee. Stick to 1–3 colors for the best pricing. Black, white, and primary colors are usually cheapest.
• Choose Simpler Artwork: Detailed gradients, fine lines, or photorealistic images increase setup time and cost. Opt for bold, vector-based designs.
• Use One-Spot Location: Printing on just the front or back is cheaper than front and back. If you must print on both sides, consider a simpler design on one side.

Optimize Artwork for Production

Proper artwork preparation prevents delays and extra charges.

• Use Vector Files (AI, EPS, SVG): These scale infinitely and are preferred by printers. Avoid low-resolution JPEGs or PNGs.
• Outline Text: Convert all text to outlines in Illustrator to prevent font issues during production.
• Set Correct Dimensions & DPI: For screen printing, artwork should be at actual print size. Use 300 DPI for digital printing.
• Submit in the Right Format: Confirm the printer’s preferred file format. Most accept PDF, PNG (transparent background), or vector files.
• Design for the Fabric: Light ink on dark shirts requires an underbase (extra layer), increasing cost. Use fewer underbases by choosing lighter inks or printing on lighter garments.

Choose the Right Printing Method

The printing technique affects both price and quality.

• Screen Printing: Best for bulk orders (50+), simple designs, and cotton shirts. Cheaper per unit at high volumes.
• DTG (Direct-to-Garment): Good for detailed, full-color designs and smaller batches. Higher per-unit cost but no setup fees.
• Heat Transfer/Vinyl: Suitable for small runs or specialty fabrics. Less durable than screen printing.

Select Cost-Effective Apparel

The shirt itself impacts your total cost.

• Choose Basic Styles: Premium or branded tees (e.g., Bella + Canvas 3001) cost more. Standard Gildan or Hanes softstyle offer great value.
• Stick to One Color: Ordering all shirts in the same color reduces setup and inventory costs.
• Consider Fabric: 100% cotton is often cheaper than blends, especially in bulk.

Final Tips to Save More

• Order Early: Rush fees can double your cost. Plan ahead.
• Bundle with Accessories: Some vendors offer discounts when ordering hats, hoodies, or tote bags with shirts.
• Ask for Samples: Check print quality before committing to a large order—avoid costly reprints.
• Negotiate: For very large orders (250+), contact suppliers directly to negotiate custom pricing.

By leveraging quantity breaks, simplifying your design, and preparing print-ready artwork, you can significantly reduce the cost of your custom t-shirt order—without sacrificing quality.