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

100% Cotton vs. 50/50 Blend vs. Tri-blends: Your Guide to Choosing the Perfect Custom T-Shirt Fabric

When designing custom t-shirts, the fabric you choose plays a crucial role in comfort, durability, appearance, and overall customer satisfaction. The most common options—100% cotton, 50/50 blends, and tri-blends—each offer distinct advantages and trade-offs. Here’s a breakdown to help you select the best fabric for your custom apparel needs.

100% Cotton: The Classic Choice

Pros:
– Soft and breathable: Ideal for everyday wear, especially in warmer climates.
– Natural feel: Offers a traditional, comfortable hand feel that many people prefer.
– Excellent printability: Holds screen printing and direct-to-garment (DTG) inks well, resulting in vibrant, crisp designs.
– Biodegradable and eco-friendly: A renewable resource that breaks down naturally.

Cons:
– Prone to shrinking: Especially if not pre-shrunk or washed in hot water.
– Less durable: More susceptible to wear, pilling, and stretching over time.
– Wrinkles easily: Requires ironing for a polished look.
– Absorbs moisture: Can feel damp when sweating since it retains water.

Best For: Casual wear, promotional events, eco-conscious brands, and designs requiring bold, detailed prints.

50/50 Blend (50% Cotton, 50% Polyester): The Balanced Option

Pros:
– Improved durability: Polyester adds strength and resistance to shrinking and stretching.
– Less wrinkling: Holds its shape better and requires less ironing.
– Faster drying: Wicks moisture more efficiently than cotton, making it more comfortable during light activity.
– Affordable: Often priced between 100% cotton and tri-blends.

Cons:
– Slightly less soft: Can feel coarser than 100% cotton, especially in lower thread counts.
– Less breathable: Polyester doesn’t breathe as well, which may lead to overheating in warm conditions.
– Pilling potential: May develop small fabric balls over time with friction.

Best For: Workwear, school uniforms, athletic events, and budget-friendly custom shirts that still look professional.

Tri-blend (Typically 50% Polyester, 25% Cotton, 25% Rayon): The Premium Pick

Pros:
– Ultra-soft and smooth: Has a luxurious, vintage-inspired drape and feel.
– Excellent drape and fit: Flatters the body and moves naturally with the wearer.
– Reduced shrinkage: More stable than 100% cotton due to synthetic fibers.
– Moisture-wicking: Polyester helps pull sweat away from the skin.

Cons:
– Higher cost: More expensive due to the blend and manufacturing process.
– Less opaque: Can be slightly sheer, especially in lighter colors.
– Delicate care: May require gentle washing to maintain softness and prevent damage.
– Print limitations: Can be tricky for certain printing methods; may require specialty inks.

Best For: Fashion-forward brands, boutique apparel, gift items, and designs aiming for a soft, lived-in aesthetic.

How to Choose the Right Fabric

• Consider the use case: Is it for daily wear, events, or performance?
• Know your audience: Prioritize comfort, durability, or style based on customer preferences.
• Match the print method: DTG and screen printing work best on cotton-heavy fabrics; sublimation suits polyester blends.
• Factor in budget: Tri-blends cost more than 50/50 or 100% cotton options.
• Think about care instructions: Will customers machine-wash regularly? Choose low-maintenance blends for ease.

By understanding the strengths and weaknesses of each fabric type, you can confidently select the ideal material for your custom t-shirts—ensuring comfort, quality, and lasting appeal.

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

Ordering custom T-shirts in bulk can be a cost-effective way to promote your brand, event, or team—but getting the best price requires strategy. Here’s how to save money while maintaining quality, with a focus on bulk pricing and artwork optimization.

Take Advantage of Bulk Quantity Breaks

Most custom apparel suppliers offer tiered pricing based on order volume. The more shirts you order, the lower the price per unit. Here’s how to maximize these savings:

• Order in Larger Quantities: Prices typically drop at thresholds like 50, 100, 250, and 500 units. If your budget allows, jump to the next tier to reduce per-unit cost.
• Combine Orders: Coordinate with other departments, teams, or organizations to pool orders and reach higher quantity breaks.
• Plan Ahead: Forecast your needs for the year. Ordering in one large batch is often cheaper than multiple small reorders.
• Choose Standard Sizes and Colors: Custom colors or hard-to-find sizes can increase costs. Stick to popular options to keep prices down.

Optimize Your Artwork for Lower Printing Costs

The design complexity directly affects printing costs. Follow these tips to keep artwork simple and affordable:

• Limit Print Colors: Each additional color increases setup and printing costs. Stick to 1–3 colors, especially for screen printing.
• Use Vector Art: Provide logos and graphics in vector formats (AI, EPS, SVG) to avoid extra fees for artwork redrawing.
• Simplify the Design: Avoid fine details or gradients that require high-resolution printing techniques like DTG (Direct-to-Garment), which are more expensive.
• Stick to One Print Location: Printing on the front only is cheaper than front and back. Choose the most impactful location.
• Repurpose Designs: Use the same design across different shirt colors instead of creating multiple unique designs.

Choose the Right Printing Method

Different printing techniques suit different order sizes and designs:

• Screen Printing: Best for large orders with simple designs. Low per-unit cost after setup.
• DTG (Direct-to-Garment): Ideal for detailed, full-color designs or small batches. Higher per-shirt cost.
• Heat Transfer: Good for short runs or complex designs, but less durable and more costly over time.

Compare Multiple Vendors

Don’t settle for the first quote. Request pricing from several reputable suppliers and compare:

• Unit cost at various quantities
• Setup fees and color charges
• Artwork assistance and revision policies
• Turnaround time and shipping costs

Look for suppliers that offer free mockups and no minimums (if applicable) to test quality before committing.

Final Tips for Best Pricing

• Ask about discounts for nonprofits, schools, or repeat customers.
• Order off-season (avoid peak summer/sports seasons) for better deals.
• Consider blank shirt quality—mid-tier garments offer a good balance of cost and comfort.
• Always get a physical sample before placing a large order.

By leveraging bulk pricing, simplifying artwork, and choosing the right printing method, you can get high-quality custom T-shirts at the best possible price.