Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

Guide to Choosing Fabrics for Custom T-Shirt Printing Near Me: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

When ordering custom t-shirts locally, selecting the right fabric is crucial for comfort, durability, and print quality. The most common fabric options are 100% cotton, 50/50 blends, and tri-blends. Here’s a breakdown to help you choose the best option for your custom t-shirt printing needs.

1. 100% Cotton

• Feel & Comfort: Soft, breathable, and ideal for everyday wear, especially in warmer climates.
• Durability: Holds up well to frequent washing but may shrink slightly if not pre-shrunk.
• Print Quality: Excellent for screen printing and direct-to-garment (DTG) printing—inks adhere smoothly for vibrant designs.
• Best For: Casual wear, promotional events, and customers who prefer a classic, natural fabric feel.

2. 50/50 Blend (50% Cotton, 50% Polyester)

• Feel & Comfort: Slightly lighter and more durable than 100% cotton, with reduced shrinkage.
• Durability: More resistant to wear and fading; retains shape better over time.
• Print Quality: Good for screen printing; may require pretreatment for DTG printing to prevent ink bleed.
• Best For: Active environments, employee uniforms, or situations requiring long-lasting shirts.

3. Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

• Feel & Comfort: Ultra-soft, with a smooth, vintage-like drape. Often described as “buttery” or “luxe.”
• Durability: Less durable than cotton or 50/50 blends—best for light to moderate wear.
• Print Quality: Excellent for DTG printing with rich color saturation, but may require special settings due to polyester content.
• Best For: Fashion-forward designs, boutique-style apparel, or gifts where softness is a priority.

How to Choose the Right Fabric for Your Needs

• Consider the Use: For workwear or sports, go for 50/50 blends. For gift shirts or stylish streetwear, tri-blends shine.
• Budget: 100% cotton and 50/50 blends are usually more affordable than tri-blends.
• Printing Method: Confirm with your local print shop which fabrics work best with their equipment—some blends require special pretreatment.
• Local Availability: Ask nearby custom t-shirt printing shops what fabric options they stock to reduce lead time.

By understanding the differences between 100% cotton, 50/50 blends, and tri-blends, you can make an informed decision that balances comfort, durability, and print quality—ensuring your custom t-shirts look great and feel even better.

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

Looking to order custom t-shirts in bulk? Whether it’s for a team, event, business, or promotional campaign, getting the best deal requires smart planning and preparation. Here’s how to maximize savings through bulk pricing and ensure your artwork translates perfectly.

Understand Bulk Quantity Breaks

One of the biggest ways to save is by ordering in larger quantities. Most reputable custom printing companies offer tiered pricing, where the price per shirt drops significantly as your order size increases.

• Know the Tiers: Common bulk breaks are at 24, 48, 72, 100, 250, and 500+ pieces. The steepest discounts usually happen between 24-48 and 48-100 units. Going from 47 to 48 shirts can slash your cost per unit dramatically.
• Order Ahead: If you anticipate needing shirts in the future (e.g., for recurring events), consider ordering slightly more now to hit a higher discount tier. Just ensure you have storage.
• Compare Quotes at Multiple Tiers: Get quotes for 48, 100, and 250 pieces even if you only need 60. The savings from ordering 100 might justify the extra inventory.

Optimize Your Design for Cost Efficiency

Your artwork directly impacts printing costs. Simpler designs are cheaper to produce.

• Minimize Print Colors: Each additional ink color requires a separate screen (in screen printing) or pass (in DTG), increasing setup time and cost. Stick to 1-3 colors whenever possible. Black and white or single-color designs are the most economical.
• Simplify Design Complexity: Avoid intricate details, very fine lines, or gradients (especially with screen printing). These can be harder to print cleanly and may require more expensive techniques or higher ink usage.
• Reduce Print Area: A smaller print (e.g., a small chest logo vs. a large back design) uses less ink and is faster to apply, lowering costs. Consider pocket prints or sleeve prints for minimalist branding.
• Choose the Right Printing Method:
  • Screen Printing: Best for large quantities (50+), simple designs with few colors. Lowest per-unit cost at scale.
  • Direct-to-Garment (DTG): Best for small runs, complex designs, or full-color photos. Higher per-unit cost, but no setup fees for simple designs. Bulk DTG discounts are less steep than screen printing.
  • Dye Sublimation: Ideal for all-over prints or performance wear, but requires polyester fabric. Cost-effective for bulk all-over designs.

Prepare Flawless Artwork

Proper artwork submission prevents delays, reprints, and unexpected charges.

• Use Vector Files (Best): Provide logos or designs as vector files (.ai, .eps, .svg). Vectors are resolution-independent, ensuring crisp, scalable prints at any size. This is crucial for screen printing.
• High-Resolution Raster Images (Minimum): If using raster (e.g., .png, .jpg, .tif), ensure 300 DPI (dots per inch) at the actual print size. A 2″x2″ logo needs to be 600×600 pixels at 300 DPI. Low-res images will look pixelated.
• Outline Text: If sending a vector file, convert all text to outlines (or curves) in your design software. This prevents font substitution issues if the printer doesn’t have your exact font.
• Specify Colors Accurately: Provide Pantone (PMS) color codes for exact color matching, especially important for brand consistency. Avoid relying solely on RGB/CMYK values from your monitor.
• Clear Placement Instructions: Indicate exactly where the design should go (e.g., “3 inches down from collar, centered on left chest”).

Smart Sourcing and Negotiation

• Get Multiple Quotes: Don’t settle for the first quote. Use online comparison tools or contact 3-5 local and reputable online printers. Provide identical specs (shirt type, quantity, sizes, print location, design details) for fair comparison.
• Specify Shirt Details: The type, brand, and fabric (e.g., 100% cotton vs. cotton/poly blend) significantly impact cost. Be specific but consider if a slightly different (cheaper) but still quality option works.
• Negotiate: For very large bulk orders (500+), don’t hesitate to ask if there’s any flexibility on pricing, especially if you’re building an ongoing relationship. Mention competitor quotes politely.
• Consider Local vs. Online: Local printers offer quick turnaround and easy communication but might have higher base prices. Online printers often have lower prices due to scale but factor in shipping costs and time. Weigh speed vs. savings.
• Ask About Setup Fees: Understand if there are screen setup fees (common in screen printing) and if they are waived for larger orders. Factor this into your total cost calculation.

By leveraging bulk quantity breaks, designing for efficiency, preparing perfect artwork, and shopping smartly, you’ll secure the best possible price for your custom t-shirts without sacrificing quality.