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

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

Planning a group vacation and want to commemorate the trip with custom t-shirts? The design is important, but the fabric you choose plays a huge role in comfort, durability, and how great the shirts look—especially after days of sun, sand, and adventure. Here’s a breakdown of the three most popular fabric options to help you pick the perfect one for your getaway.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and breathable: Ideal for hot weather and long days outdoors, allowing air to circulate and keeping you cool.
– Natural feel: Offers a familiar, comfortable hand feel that many people love.
– Great for screen printing: Provides a smooth, absorbent surface for vibrant, crisp designs.

Cons:
– Prone to shrinking: Especially if not pre-shrunk or washed in hot water.
– Less durable: Can wear out faster with frequent washing and heavy use.
– Holds moisture: Absorbs sweat but dries slowly, which may feel damp in humid climates.
– Wrinkles easily: Requires ironing or steaming for a polished look.

Best for: Casual beach trips, relaxed family vacations, or destinations with mild temperatures where breathability is a top priority.

50/50 Blend (50% Cotton / 50% Polyester): The Balanced Performer

Pros:
– Soft with added durability: Combines cotton’s comfort with polyester’s strength and resistance to wear.
– Resists shrinking and wrinkling: Holds its shape and look better after washing and packing.
– Faster drying: Polyester wicks moisture better than cotton alone, making it great for active days.
– Cost-effective: Often more affordable than tri-blends while offering improved performance over 100% cotton.

Cons:
– Less breathable than 100% cotton: May feel warmer in extreme heat.
– Slight sheen: Polyester can give the fabric a subtle shine, which may not appeal to everyone.
– Design feel: Prints may have a slightly different texture than on pure cotton.

Best for: Active vacations (hiking, city tours), group trips with varied activities, or when you want a shirt that looks good and lasts through multiple wears and washes.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon): Ultra-Soft and Stylish

Pros:
– Luxuriously soft: The rayon adds a silky, vintage-inspired drape that feels premium.
– Excellent drape: Flattering fit that moves with you, ideal for a relaxed, fashionable look.
– Great color retention: Vibrant prints and colors tend to stay bold over time.
– Wrinkle-resistant: Holds up well in luggage and doesn’t require ironing.

Cons:
– Less durable: Softer fibers can be more prone to pilling or snagging with rough use.
– Higher price point: Typically more expensive than cotton or 50/50 blends.
– May stretch over time: Especially if hung when wet or worn frequently.

Best for: Stylish group getaways, tropical destinations, or when you want a soft, trendy shirt that feels great and looks effortlessly cool.

Final Tips for Choosing

• Consider the climate: Hot and humid? Lean toward cotton or tri-blends. Active and sweaty? 50/50 or tri-blend for moisture management.
• Think about activities: Rough outdoor adventures call for durability—50/50 blend wins. Lounging by the pool? Go for softness—cotton or tri-blend.
• Budget matters: 100% cotton and 50/50 blends are usually more budget-friendly than tri-blends.
• Test swatches: Order fabric samples to touch and compare before placing a large order.

Choosing the right fabric ensures your vacation t-shirts are not only a fun keepsake but also comfortable and wearable throughout your trip—and for years to come.

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

Planning a family reunion, destination wedding, or group vacation? Custom vacation t-shirts are a fun way to build excitement and create lasting memories. To get the best price—especially when ordering in bulk—follow these smart strategies focused on quantity discounts and artwork optimization.

Leverage Bulk Quantity Breaks for Lower Per-Unit Costs

Most screen printing and embroidery companies offer tiered pricing based on order size. The more shirts you order, the lower your cost per shirt. Here’s how to maximize savings:

• Order in Larger Quantities: Prices often drop significantly at thresholds like 25, 50, 100, or 250 units. For example, ordering 100 shirts may cost $8 each, while 50 shirts might be $12 each.
• Coordinate with Your Group: The larger your group (e.g., extended family, wedding party, travel club), the more you benefit from bulk pricing. Encourage everyone to participate.
• Consider Future Use: If you plan annual trips, order extra shirts for next year or keep spares. Leftover inventory can still save money long-term.
• Compare Vendors with Tiered Pricing: Use online quote tools from companies like CustomInk, Printful, or local screen printers to compare price breaks across different volume tiers.

Optimize Your Artwork to Reduce Production Costs

Design complexity directly impacts printing costs. Simple, well-prepared artwork can reduce setup fees and printing time—saving you money.

• Limit Print Colors: Each additional ink color increases setup and printing costs. Stick to 1–3 colors for the lowest prices. Consider using shirt color as a design element (e.g., white ink on navy shirts).
• Use Vector Artwork: Supply logos or graphics in vector formats (AI, EPS, SVG) to avoid resizing issues and extra design fees. High-resolution PNG or PDF files are acceptable alternatives.
• Simplify Your Design: Avoid gradients, fine details, or photorealistic images, which may require costlier printing methods like direct-to-garment (DTG). Opt for bold, clean lines and solid fills.
• Minimize Print Locations: Printing on just the front or back is cheaper than multi-panel printing (front + back + sleeve). Choose one or two locations max.
• Standard Sizes and Placement: Custom placements or oversized prints can incur extra charges. Stick to standard chest or center-back positioning.

Additional Money-Saving Tips

• Choose Affordable Blank T-Shirts: Basic cotton styles (e.g., Gildan, Hanes) cost less than premium brands (e.g., Bella+Canvas, Next Level). Select a balance of comfort and price.
• Avoid Rush Fees: Place your order at least 2–3 weeks before you need the shirts. Rush processing can double shipping costs.
• Request Samples: Some vendors offer free or low-cost samples. This ensures quality and fit before committing to a large order.
• Negotiate with Local Printers: Local shops may offer discounts for bulk orders or repeat business. Don’t hesitate to ask for a better deal.

By combining smart bulk ordering with cost-effective artwork, you can create stylish, memorable vacation t-shirts without breaking the bank. Plan early, design simply, and buy in bulk to get the best value.