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

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

When designing custom t-shirts with a logo, selecting the right fabric is crucial—not only for comfort and durability but also for how well the logo prints and holds up over time. The three most common fabric types—100% cotton, 50/50 blends, and tri-blends—each offer unique advantages and trade-offs. Here’s what you need to know to make the best choice for your custom apparel.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and breathable: Ideal for everyday wear, especially in warm weather.
– Eco-friendly appeal: Natural fiber, biodegradable, and often preferred by environmentally conscious consumers.
– Great for printing: Provides a smooth, consistent surface for screen printing and direct-to-garment (DTG) printing. Ink adheres well, producing vibrant logo colors.
– Absorbs dye effectively: Solid colors are rich and consistent.

Cons:
– Prone to shrinking: Especially if not pre-shrunk; may require sizing up.
– Less durable over time: Can pill, fade, or stretch with frequent washing.
– Wrinkles easily: Requires ironing for a crisp look.

Best for: Casual wear, promotional giveaways, events in warm climates, or when a natural, classic feel is desired.

50/50 Blend: The Balanced Choice

Pros:
– Durability: Polyester adds strength, helping the shirt resist shrinking, fading, and pilling.
– Shape retention: Holds its form better after multiple washes.
– Moisture-wicking: Polyester helps draw moisture away from the body, making it slightly more performance-oriented.
– Cost-effective: Often less expensive than high-quality cotton or tri-blends.

Cons:
– Less breathable: Can feel warmer than 100% cotton, especially in hot weather.
– Slight sheen: May have a subtle synthetic look that some find less natural.
– Printing considerations: May require different ink formulas (especially for DTG), and light-colored logos can sometimes appear slightly less vibrant.

Best for: Workwear, sports teams, school events, or when durability and budget are top priorities.

Tri-blends: Softness and Style

Pros:
– Ultra-soft feel: A mix of cotton, polyester, and rayon creates a smooth, lightweight, and draping fabric often compared to vintage or luxury tees.
– Excellent drape: Flattering fit that moves well with the body.
– Reduced shrinkage: More stable than 100% cotton due to synthetic fibers.
– Vintage aesthetic: Slight texture and muted colors give a trendy, lived-in look that complements artistic or retro logos.

Cons:
– Less durable: The rayon content can make the fabric more delicate and prone to pilling or snagging.
– Higher cost: Typically more expensive than cotton or 50/50 options.
– Printing challenges: The fabric’s texture and blend can affect print clarity; pre-treatment may be needed for best results.

Best for: Fashion-forward brands, boutique merchandise, gift items, or when a premium, soft hand-feel is essential.

How Fabric Affects Logo Printing

• 100% Cotton: Offers the best ink absorption and crisp print detail. Ideal for bold, colorful logos.
• 50/50 Blend: Works well with screen printing; DTG may require adjustments for polyester content.
• Tri-blend: Requires experienced printers due to fabric sensitivity. Prints often have a softer, vintage look—great for subtle or artistic designs.

Final Tips for Choosing

• Consider your audience: Are they active, fashion-conscious, or looking for workwear?
• Think about use case: Will shirts be worn daily, at events, or as keepsakes?
• Budget wisely: Tri-blends cost more but offer a premium feel; 50/50 blends offer value and durability.
• Test first: Order samples to evaluate fabric feel, print quality, and overall look before bulk production.

By matching the fabric to your logo style, intended use, and audience preferences, you’ll ensure your custom t-shirts make a lasting impression—both in comfort and branding.

How to Get the Best Price on Custom T-Shirts with Logo (Bulk Discounts & Artwork Tips)

Ordering custom t-shirts in bulk for your business, team, or event can be cost-effective—but only if you know how to maximize savings. The key lies in leveraging quantity breaks and preparing your artwork correctly. Here’s how to get the best price without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost.

• Know the Thresholds: Common quantity breaks occur at 25, 50, 100, 250, and 500 units. Ordering just above a break (e.g., 101 instead of 99) can reduce your cost per shirt significantly.
• Plan for Growth: If you’re unsure about future needs, consider ordering slightly more to reach the next price tier. Extra shirts are often cheaper than a second small order later.
• Mix Sizes, Same Design: You can usually mix sizes (S–XXL) within the same design without increasing the price, as long as the print remains consistent.

Choose the Right Printing Method

The printing technique impacts both cost and quality. For bulk orders, screen printing is typically the most economical.

• Screen Printing: Best for large orders (50+ units) and simple designs with fewer colors. Setup costs are higher, but the per-unit price drops sharply with volume.
• DTG (Direct-to-Garment): Ideal for complex, full-color designs or small runs. Less cost-effective for bulk orders due to slower production and higher per-shirt costs.
• Embroidery: Great for logos on polos or hats, but more expensive. Consider it only if branding durability is a priority.

Optimize Your Artwork for Lower Costs

Your logo design can directly affect pricing—especially with screen printing.

• Simplify Your Design: Fewer colors mean fewer screens and lower setup fees. Stick to 1–3 colors whenever possible.
• Use Vector Files: Provide your logo in vector format (AI, EPS, or SVG). This ensures crisp printing at any size and avoids extra artwork conversion fees.
• Avoid Gradients and Complex Effects: These often require simulated process printing or DTG, which increases cost. Opt for solid colors and clean lines.
• Confirm Size and Placement: Specify exact logo dimensions and placement (e.g., left chest, center back). Avoid rework charges by getting it right the first time.

Compare Multiple Suppliers

Don’t settle for the first quote. Get estimates from at least 3–5 suppliers.

• Look Beyond Price: Check reviews for quality, turnaround time, and customer service. A slightly higher price with reliable delivery may save money in the long run.
• Ask About Hidden Fees: Inquire about setup fees, ink colors, blank shirt quality, and shipping costs. Some vendors advertise low prices but add fees later.
• Request a Physical Sample: Many suppliers offer a sample shirt for a small fee. This lets you assess print quality and fabric before committing to a large order.

Time Your Order Strategically

• Avoid Rush Fees: Standard production times are 7–14 days. Rush orders can double your cost. Plan ahead, especially for events.
• Watch for Promotions: Some companies offer seasonal discounts or first-time customer deals. Subscribe to newsletters or follow them on social media.

Final Tips for Maximum Savings

• Buy Blank Shirts in Bulk: If you’re doing internal printing, buying blanks wholesale and printing in-house can save money over time.
• Stick to Standard Colors: Basic colors (black, white, navy) are cheaper than fashion or neon shades.
• Negotiate: For very large orders (500+), don’t hesitate to ask for a better rate. Long-term partnerships often lead to discounts.

By leveraging quantity breaks, simplifying your artwork, and choosing the right supplier, you can significantly reduce the cost per shirt—without compromising on professionalism or brand quality.