Comparison of Custom T-Shirt Printing Methods

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing Fabrics for Custom Text T-Shirts

Choosing the right fabric is essential for creating a custom text T-shirt that looks great, feels comfortable, and lasts. The three most popular fabric options—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits and trade-offs. Here’s how to decide which is best for your custom design.

100% Cotton

Pros:
– Soft and Breathable: Pure cotton is naturally soft, especially after a few washes, and allows air to circulate, making it ideal for warm weather.
– Eco-Friendly: Cotton is a natural, biodegradable fiber, appealing to environmentally conscious buyers.
– Great for Printing: Provides a smooth, consistent surface for high-contrast, vibrant prints—perfect for bold text and designs.
– Classic Feel: Offers that traditional “cotton T-shirt” feel that many people love.

Cons:
– Prone to Shrinking: Can shrink significantly in the dryer, especially if not pre-shrunk.
– Less Durable: May wear out faster than blended fabrics, especially with frequent washing.
– Wrinkles Easily: Tends to wrinkle more than synthetic blends.
– Holds Moisture: Absorbs sweat but dries slowly, which may feel damp during heavy activity.

Best For: Casual wear, vintage or classic styles, eco-conscious consumers, and bold, high-contrast text designs.

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

Pros:
– Durable and Long-Lasting: Polyester adds strength and helps the shirt resist pilling and shrinking.
– Less Wrinkling: Holds its shape better and resists wrinkles compared to 100% cotton.
– Affordable: Typically less expensive than tri-blends and offers a good balance of comfort and performance.
– Moisture-Resistant: Dries faster than cotton and resists sweat stains better.

Cons:
– Less Soft: Can feel slightly rougher or less breathable than 100% cotton.
– Less Eco-Friendly: Polyester is a synthetic fiber derived from petroleum.
– Print Appearance: May give prints a slightly softer or more muted look due to the fabric texture.

Best For: Workwear, promotional events, active lifestyles, and budget-friendly custom shirts with text that needs to hold up over time.

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

Pros:
– Ultra-Soft Feel: Often described as “buttery soft” with a slight drape, offering a premium hand feel.
– Excellent Drape: Flatters the body and reduces boxiness, ideal for fashion-forward styles.
– Fade-Resistant: Polyester and rayon help the fabric resist fading and maintain color over time.
– Wrinkle-Resistant: Holds up well after washing and wearing.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Less Breathable: May not be as breathable as pure cotton during intense physical activity.
– Delicate Care: Requires gentle washing (cold water, hang dry) to maintain softness and prevent shrinkage.
– Print Limitations: The fabric’s texture can slightly affect print clarity, especially for very fine text.

Best For: Fashion tees, boutique-style apparel, gifts, or premium custom text shirts where comfort and aesthetics are top priorities.

Final Tips for Choosing

• Consider the Audience: Athletes may prefer 50/50 blends; eco-conscious buyers lean toward cotton; fashion lovers love tri-blends.
• Think About Care: Will the shirt be washed frequently? Tri-blends require more care.
• Evaluate Print Needs: High-contrast text pops best on cotton; softer text designs can shine on tri-blends.
• Budget Matters: Tri-blends cost more—balance quality with your budget.

By understanding these differences, you can confidently select the perfect fabric to make your custom text T-shirt a success.

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

When ordering custom text t-shirts in bulk, getting the best price isn’t just about finding the cheapest vendor—it’s about smart planning, understanding pricing structures, and optimizing your design. Here’s how to save money without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order size. The more you order, the lower the per-unit cost.

• Know the thresholds: Common quantity breaks include 12, 24, 48, 72, 100, and 250 units. For example, 48 shirts might cost $10 each, but 72 could drop to $8.50 each.
• Order to the next break: If you need 60 shirts, consider ordering 72 to take advantage of the lower per-unit rate—extra shirts can be used as backups or future inventory.
• Mix sizes and colors wisely: Many printers allow size and color variations within the same order without extra fees, as long as the design and quantity stay consistent.

Choose the Right Printing Method

The printing technique impacts both cost and quality.

• Screen Printing: Best for large orders (50+ units) with simple text designs. Low cost per shirt after setup, especially with 1–3 ink colors.
• Direct-to-Garment (DTG): Ideal for smaller runs or full-color text effects (like gradients). Higher per-unit cost, but no setup fees for complex designs.
• Heat Transfer or Vinyl: Cost-effective for very small batches or names/numbers, but less durable than screen printing.

Simplify Your Text Design

Complex artwork drives up costs. Keep your text design clean and printer-friendly.

• Limit colors: Each additional ink color increases setup and printing costs. Stick to 1–2 colors when possible.
• Use vector text: Provide artwork in vector format (AI, EPS, or SVG) so text remains sharp at any size. Avoid low-resolution PNGs or JPEGs.
• Avoid gradients and effects: Fancy text effects (glows, drop shadows, gradients) may require DTG or complex screens, increasing cost. Use solid colors instead.

Optimize Your Artwork for Production

Proper file preparation prevents delays and extra charges.

• Outline all text: Convert text to outlines in your design software to avoid font licensing or missing font issues.
• Include a mockup: Provide a clear placement guide showing where the text should appear (center chest, full back, etc.).
• Specify exact colors: Use Pantone (PMS) or CMYK values to ensure color accuracy. Avoid vague descriptions like “dark blue.”

Compare Multiple Suppliers

Don’t settle for the first quote.

• Request bulk quotes: Provide exact specs (size, color, quantity, design details) to get accurate comparisons.
• Check for hidden fees: Ask about setup fees, screen fees, or rush charges. Some vendors waive fees for large orders.
• Read reviews: Look for feedback on print quality, color matching, and delivery times.

Time Your Order Strategically

• Avoid peak seasons: Ordering during holidays or back-to-school periods may result in higher prices or longer lead times.
• Ask about discounts: Some printers offer seasonal promotions, referral discounts, or loyalty programs for repeat customers.

Final Tips for Maximum Savings

• Order slightly more than needed: Use quantity breaks to your advantage; leftover shirts are cheaper than a second small order.
• Standardize shirt types: Ordering all the same brand and style simplifies production and reduces costs.
• Negotiate: For large orders (100+), don’t hesitate to ask for a better rate—many suppliers are willing to work with you.

By leveraging bulk pricing, simplifying your design, and preparing professional artwork, you can get high-quality custom text t-shirts at the best possible price.