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

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

When creating custom t-shirts featuring photos, selecting the right fabric is crucial for both print quality and overall comfort. The three most popular fabric types—100% cotton, 50/50 blends, and tri-blends—each offer distinct advantages and trade-offs. Here’s a detailed comparison to help you make the best choice for your photo-printed tees.

100% Cotton: Classic Comfort and Softness

Pros:
– Superior Softness: Offers a naturally soft, breathable feel that’s ideal for everyday wear.
– Excellent Print Clarity: Provides a smooth, consistent surface that enhances photo detail and color vibrancy, especially with high-resolution images.
– Eco-Friendly Option: Natural fiber that’s biodegradable and often available in organic variants.
– Great for Vintage Aesthetic: Ages well with a slightly worn-in look after multiple washes.

Cons:
– Prone to Shrinking: May shrink if not pre-shrunk or washed in hot water.
– Less Durable: Can wear out faster over time, especially with frequent washing.
– Wrinkles Easily: Tends to crease more than blended fabrics.

Best For: High-quality photo prints where softness and a natural feel are priorities—perfect for gifts, keepsakes, or premium apparel.

50/50 Blend (50% Cotton / 50% Polyester): Balanced Performance

Pros:
– Durability: Polyester adds strength, making the shirt more resistant to shrinking, fading, and pilling.
– Cost-Effective: Often more affordable than 100% cotton or tri-blends.
– Low Maintenance: Resists wrinkles and dries quickly, making it ideal for active use or promotional apparel.
– Good Print Results: Handles photo printing well, though colors may not be as rich as on 100% cotton.

Cons:
– Slightly Less Soft: The polyester content can make the fabric feel less breathable and slightly coarser.
– Less Absorbent: Doesn’t wick moisture as effectively as pure cotton.

Best For: Everyday wear, promotional events, or team shirts where durability and consistent sizing are key—ideal for large photo prints that need to withstand regular use.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon): Premium Softness and Drape

Pros:
– Luxurious Feel: Offers a buttery-soft texture with a slight stretch and excellent drape, resembling a vintage tee.
– Reduced Shrinkage: The polyester and rayon content help maintain shape and size over time.
– Enhanced Vibrancy: Rayon adds a subtle sheen that can make photo colors pop with a unique, premium look.
– Great Drape and Fit: Hugs the body comfortably without clinging, ideal for fashion-forward designs.

Cons:
– Higher Cost: Typically the most expensive option due to the blend complexity.
– Delicate Care Required: May require gentler washing to preserve softness and prevent pilling.
– Slight Sheerness: Some tri-blend fabrics can be slightly sheer, especially in lighter colors.

Best For: High-end custom t-shirts with detailed photo prints, fashion apparel, or gifts where comfort, drape, and a modern aesthetic are essential.

Final Tips for Choosing Based on Your Photo

• High-Resolution Photos: 100% cotton and tri-blends tend to render fine details and gradients better.
• Bold, Graphic Images: 50/50 blends provide excellent durability with strong color contrast.
• Vintage or Artistic Effect: Tri-blends enhance retro or soft-focus photos with their unique texture.
• Budget and Volume: 50/50 blends offer the best balance of cost, durability, and print quality for bulk orders.

By understanding the characteristics of each fabric, you can select the best option to showcase your photo on a custom t-shirt—ensuring both visual impact and lasting comfort.

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

Ordering custom t-shirts with photos in bulk can be a cost-effective way to promote your brand, event, or team—but getting the best price requires strategy. From leveraging quantity breaks to optimizing your artwork, here’s how to save money without sacrificing quality.

Understand Bulk Quantity Breaks

Most custom apparel suppliers offer discounted pricing based on the number of shirts you order. These are called quantity breaks.

• Common Break Points: Typically, prices drop at 25, 50, 100, 250, and 500+ units.
• Example:
• 25 shirts: $12 each
• 50 shirts: $9 each
• 100 shirts: $7 each

Tip: Order slightly more than you think you need to hit the next pricing tier. Leftover shirts are cheaper than reordering later.

• Compare Vendors: Use online quote tools from multiple suppliers (e.g., Printful, Custom Ink, RushOrderTees) to find the best bulk rates.
• Subscribe to Deals: Sign up for vendor newsletters—many offer limited-time discounts on bulk orders.

Optimize Your Photo Artwork for Lower Costs

High-quality printing starts with great artwork. Poor images can lead to extra charges or the need for design revisions.

Use High-Resolution Images

• Minimum Resolution: 300 DPI (dots per inch) at the actual print size.
• File Size Tip: A full-front print (12” x 14”) needs an image at least 3600 x 4200 pixels.
• Avoid Stretching: Never enlarge low-res photos—this causes pixelation.

Choose the Right File Format

• Best Formats: PNG (for transparency) or TIFF (high quality)
• Acceptable: High-quality JPEG (use with caution)
• Avoid: Low-quality JPEGs, screenshots, or social media images (often compressed)

Simplify Your Design

• Fewer Colors = Lower Cost: Full-color photos use Direct-to-Garment (DTG) printing, which is pricier than screen printing. Simplify backgrounds or use color reduction tools.
• Crop Smartly: Focus on the key part of the photo to reduce ink coverage and printing cost.
• Use Vector Overlays: Add text or logos in vector format (SVG, EPS) to prevent blurriness.

Select the Right Printing Method

The printing technique affects both price and quality.

• Direct-to-Garment (DTG):
• Best for full-color photos and detailed images.
• Cost-effective for small to medium runs (under 100 units).

• Higher per-unit cost than screen printing.

• Dye Sublimation:

• Ideal for all-over prints and vibrant colors.
• Requires polyester garments (can increase shirt cost).

• Great for consistent photo quality.

• Screen Printing with Photo Simulation:

• Uses halftones and color blending to mimic photos.
• Cheaper for large orders, but less detail.
• Best for simpler photo designs or silhouettes.

Choose Affordable, High-Quality Garments

• Standard Cotton Blends: 100% cotton or cotton/poly blends are often the most affordable.
• Avoid Premium Brands: Basic brands (e.g., Gildan, Hanes, Bella+Canvas) offer bulk discounts.
• Stick to One Style: Using a single shirt style reduces setup and fulfillment costs.

Order All at Once

• Avoid Multiple Shipments: Consolidating your order saves on setup fees and shipping.
• Plan Ahead: Bulk pricing only works if you can commit to a large order upfront.

Request a Physical Sample

Before placing a large order:
– Order one sample shirt to test print quality.
– Confirm color accuracy and fabric feel.
– This avoids costly reprints due to unexpected results.

Final Tips to Save More

• Group Orders: Combine needs with other teams or departments to reach higher quantity breaks.
• Seasonal Promotions: Look for holiday sales or end-of-quarter deals.
• Negotiate: For very large orders (500+), contact sales reps directly—many offer custom quotes and discounts.

By leveraging bulk pricing, optimizing your artwork, and choosing the right printing method, you can get stunning custom photo t-shirts at the lowest possible cost.