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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Right Fabric for Custom T-Shirt Screen Printing

When designing custom t-shirts for screen printing, the fabric you choose significantly impacts the final look, feel, durability, and print quality. Understanding the differences between popular fabric types—100% cotton, 50/50 blends, and tri-blends—helps ensure your project meets both aesthetic and functional goals. Here’s a detailed comparison to guide your decision.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, comfortable feel, especially in classic styles like ring-spun or combed cotton.
– Excellent Print Surface: Absorbs ink well, resulting in vibrant, crisp designs with strong opacity.
– Eco-Friendly Appeal: Biodegradable and often preferred by customers seeking sustainable, natural materials.
– Classic Look and Feel: Ideal for traditional, vintage, or heritage-style apparel.

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk, especially after washing.
– Less Durable Over Time: Can wear out faster, pill more easily, and lose shape with repeated washing.
– Wrinkles Easily: Requires ironing or steaming for a polished appearance.

Best For: Eco-conscious brands, vintage designs, promotional tees, and customers who prioritize natural fibers and comfort over durability.

50/50 Cotton-Polyester Blend

Pros:
– Reduced Shrinkage: Polyester adds stability, minimizing shrinkage compared to 100% cotton.
– Durability: More resistant to wear, fading, and pilling—ideal for frequent use or workwear.
– Affordable: Typically less expensive than higher-end cotton or tri-blend fabrics.
– Good Print Performance: Holds screen prints well, though ink may sit slightly more on the surface.

Cons:
– Less Breathable: Polyester reduces airflow, making shirts feel warmer in hot climates.
– Slight Sheen: Can have a subtle synthetic shine, which may not suit matte or vintage designs.
– Pilling Potential: May develop small fabric balls over time, especially with friction.

Best For: Budget-friendly bulk orders, event shirts, employee uniforms, and active-wear where durability is key.

Tri-Blends (Typically Cotton, Polyester, and Rayon)

Pros:
– Ultra-Soft Hand Feel: Blends often feel buttery soft and drapier, similar to a lightweight sweater.
– Excellent Drape: Flatters the body with a more tailored, fashion-forward fit.
– Minimal Shrinkage: Stable fabric that retains shape and size after washing.
– Vintage Aesthetic: Ideal for retro or soft-style prints with muted, lived-in vibes.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends due to premium fibers.
– Ink Absorption Variability: Rayon can absorb more ink, possibly requiring adjustments in print technique for optimal results.
– Less Durable in High-Stress Areas: May wear faster at seams or underarms with heavy use.

Best For: Fashion-forward brands, boutique apparel, gift items, and designs where softness and drape are prioritized.

Final Tips for Choosing Your Fabric

• Consider the End Use: Is it for daily wear, events, or fashion statements?
• Think About Your Audience: Do they value sustainability, comfort, or durability?
• Test Print First: Always run a sample print on your chosen fabric to assess ink adhesion and appearance.
• Check Garment Specifications: Review fabric weight (e.g., 4.5 oz vs. 6.1 oz) and construction for consistency.

By matching your fabric choice to your brand’s vision and customer needs, you’ll create custom screen-printed t-shirts that look great, feel comfortable, and stand the test of time.

How to Get the Best Price for Custom T-Shirt Screen Printing (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 understanding quantity breaks and optimizing your artwork, you can significantly reduce costs without sacrificing quality. Here’s how:

Leverage Bulk Quantity Breaks

Screen printing is most cost-effective when done in large quantities because setup costs (like screen creation and machine setup) are spread across more units. Most printers offer tiered pricing based on volume. To maximize savings:

• Order in Larger Quantities: Prices per shirt drop significantly at common thresholds (e.g., 50, 100, 250, 500+ units). For example, ordering 250 shirts may cost $5 each, while 50 shirts might be $8 each.
• Consolidate Orders: If multiple teams or departments need shirts, combine orders to reach higher quantity tiers.
• Plan Ahead: Bulk printing reduces rush fees and gives you inventory for future events.

Optimize Your Artwork for Lower Printing Costs

Design choices directly impact printing complexity and cost. Simple designs save time and materials:

• Use Fewer Colors: Each color requires a separate screen and pass through the press. Stick to 1–3 colors to keep costs low.
• Simplify Your Design: Avoid gradients, fine details, or photorealistic images. Bold, solid graphics print faster and more affordably.
• Provide High-Resolution Files: Supply vector artwork (e.g., .AI, .EPS, or .PDF) or high-res raster files (300 DPI). This prevents delays and extra charges for file rebuilding.
• Stick to Standard Print Locations: Chest prints or back prints are cheaper than full sleeves or all-over printing.

Choose the Right Shirt Style and Color

• White or Light-Colored Shirts: Cheaper to print on, especially with water-based or discharge inks.
• Standard Cotton Blends: Basic 100% cotton or cotton/polyester blends are more affordable than premium or specialty fabrics.
• Stick to One Style: Mixing shirt types increases setup time and cost.

Compare Multiple Printers and Negotiate

• Get quotes from at least 3–5 reputable screen printers.
• Ask about bundled deals, repeat customer discounts, or off-season promotions.
• Negotiate setup fee waivers for large or recurring orders.

Proof Before Printing

Always request a digital or physical proof. Catching errors early prevents costly reprints and delays.

By combining bulk ordering, simplified artwork, and smart vendor selection, you can get professional custom t-shirts at the most competitive price. Plan early, design smart, and print in volume for the best results.