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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Best Fabric for Custom T-Shirts with Faces

When creating custom t-shirts featuring faces—whether it’s a portrait, a celebrity, a pet, or a character—the fabric you choose plays a crucial role in how the image turns out and how the shirt feels to wear. Here’s a breakdown of the three most popular fabric options to help you make the best choice.

100% Cotton: Classic Comfort with a Crisp Print

Pros:
– Superior Print Clarity: 100% cotton provides a smooth, stable surface that’s ideal for high-resolution face prints. The ink sits well on the fabric, offering vibrant colors and sharp details—critical for capturing facial features.
– Soft and Breathable: Natural cotton fibers are breathable and comfortable, especially in warmer climates. Over time, they tend to soften with each wash.
– Eco-Friendly Option: As a natural fiber, cotton is biodegradable and often preferred for sustainable apparel.

Cons:
– Prone to Shrinking: 100% cotton shirts can shrink after washing, particularly if not pre-shrunk. This may slightly distort the face design.
– Less Durable Over Time: Cotton can fade or wear out faster than blended fabrics, especially after repeated washes.
– Wrinkles Easily: These shirts tend to wrinkle more, which may affect the appearance of the printed face.

Best For: Classic tees where print quality and natural comfort are top priorities. Ideal for portrait-heavy designs on lightweight to midweight garments.

50/50 Blend: The Best of Both Worlds

Pros:
– Durability: A 50% cotton / 50% polyester blend resists shrinking and fading better than 100% cotton, helping your face design stay vibrant longer.
– Wrinkle-Resistant: The polyester content helps the shirt hold its shape and resist creasing.
– Affordable and Practical: Offers a good balance of comfort, cost, and performance—perfect for promotional or everyday wear.

Cons:
– Slightly Less Breathable: Polyester doesn’t breathe as well as cotton, which may make the shirt feel warmer.
– Print Quality Can Vary: While modern printing techniques handle blends well, the texture of 50/50 blends can sometimes result in a slightly softer (less crisp) image compared to 100% cotton.

Best For: Workwear, giveaways, or casual tees where durability and cost-effectiveness matter. Good for facial prints if using high-quality printing methods like direct-to-garment (DTG).

Tri-Blend: Softness and Style in One

Pros:
– Ultra-Soft Feel: Typically made from a mix of cotton, polyester, and rayon (e.g., 50%/25%/25%), tri-blends have a lightweight, silky texture that drapes beautifully.
– Vintage Aesthetic: These shirts often have a slightly heathered look, giving facial prints a trendy, retro vibe.
– Excellent Drape and Fit: The fabric is less stiff and conforms well to the body, making it flattering for all body types.

Cons:
– Higher Cost: Tri-blend shirts are usually more expensive due to the materials and manufacturing process.
– Delicate Printing Surface: While DTG printing works well, the rayon content can sometimes make colors appear slightly muted compared to 100% cotton.
– Less Structured: The soft drape may not hold up as well in very detailed facial prints, especially on larger designs.

Best For: Fashion-forward tees, gifts, or artistic projects where comfort and aesthetics are key. Great for stylized or vintage-inspired face designs.

Final Tips for Printing Faces on Custom T-Shirts

• High-Resolution Artwork: Regardless of fabric, always use high-resolution (300 DPI or higher) images to ensure facial details remain sharp.
• Color Accuracy Matters: Request a print proof, especially for skin tones and intricate facial features.
• Test Print First: Order a sample to see how the face looks on each fabric type before bulk production.
• Consider the Wear Context: Think about how and where the shirt will be worn—this can guide your fabric choice.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can select the perfect fabric to make your custom face design stand out—both in print quality and comfort.

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

Creating custom t-shirts featuring faces—whether for a sports team, event, business, or personal project—can be a memorable and impactful way to promote unity or celebrate a moment. However, these designs often come with higher printing costs due to complexity. The good news? You can significantly reduce your expenses with smart bulk ordering and proper artwork preparation. Here’s how.

Leverage Bulk Quantity Breaks

One of the most effective ways to lower your per-unit cost is by ordering in larger quantities. Most reputable print-on-demand and screen printing companies offer tiered pricing based on volume.

• Understand Quantity Tiers: Printing companies typically offer price breaks at certain quantities (e.g., 25, 50, 100, 250, 500+). For example:
• 10–24 shirts: $15 each
• 25–49 shirts: $12 each
• 50–99 shirts: $9 each
• 100+ shirts: $7 each

Ordering 100 shirts instead of 25 could save you hundreds of dollars.

• Consolidate Orders: If you’re part of an organization or event, pool orders with others to reach higher tiers. Even if people want different designs, some suppliers allow mixed designs within the same order if colors and garment types are consistent.

• Choose Simpler Garments: Opt for basic, in-stock t-shirt styles (like Gildan or Hanes) instead of premium or fashion-cut options. Simpler shirts reduce both base cost and setup fees.

• Stick to One Location and Color Palette: Printing all designs on the same spot (e.g., front chest) and limiting the number of ink colors reduces setup and labor costs.

Optimize Your Artwork for Lower Printing Costs

The complexity of your face artwork directly affects pricing—especially with screen printing. High-detail faces with gradients and shading require more screens and labor, driving up costs.

• Use Vector Art When Possible: Provide your artwork in vector format (AI, EPS, or SVG). Vector files scale infinitely without losing quality, making them ideal for printing. If you’re using a photo, convert it to a high-resolution vector outline.

• Simplify the Design:

• Convert photos to silhouettes or line drawings to reduce ink usage.
• Use high-contrast black-and-white versions instead of full-color photos.

• Limit your design to 1–3 colors max to cut down on screen setup fees.

• Follow Print Provider Guidelines:

• Submit artwork at 300 DPI resolution.
• Use proper file formats (PNG with transparent background for DTG; vector for screen printing).

• Keep important elements at least 1 inch from seams and hems.

• Consider Direct-to-Garment (DTG) for Small Runs: For under 50 shirts or full-color faces, DTG printing is often more affordable and detailed than screen printing. It works like an inkjet printer and handles complex images well.

• Use Halftones for Shading: Instead of solid gradients, use halftone patterns to simulate shading with just one ink color. This reduces the number of screens needed.

Additional Cost-Saving Tips

• Get Multiple Quotes: Compare pricing from at least 3–5 suppliers (e.g., Printful, Custom Ink, RushOrderTees, local screen printers). Some specialize in low minimums; others offer better bulk deals.

• Avoid Rush Fees: Plan ahead. Rush orders can increase costs by 25–50%. Place your order at least 2–3 weeks before you need the shirts.

• Reuse Screens: If you plan future reorders with the same design, ask if the printer can store screens. Reprinting later without new setup fees saves money.

• Negotiate: For large orders (250+), don’t hesitate to ask for a discount. Many suppliers are willing to negotiate to secure big clients.

By combining smart bulk ordering with streamlined artwork, you can achieve professional-looking custom t-shirts with faces at a fraction of the expected cost. Plan early, design simply, and order big—your budget will thank you.