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 Fabric for Custom T-Shirts

When creating custom t-shirts, selecting the right fabric is crucial for both comfort and print quality. The three most popular options—100% cotton, 50/50 blends, and tri-blends—each offer unique benefits. Understanding their differences will help you choose the best material for your needs.

100% Cotton: Classic Comfort and Softness

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear.
– Natural feel: Offers a classic, familiar texture that many people love.
– Excellent print surface: Absorbs ink well, resulting in vibrant, crisp designs—especially with screen printing.
– Biodegradable: An eco-friendly option at the end of its life cycle.

Cons:
– Prone to shrinking: May shrink during washing if not pre-shrunk.
– Less durable: Can wear out faster and may pill over time.
– Wrinkles easily: Requires ironing for a crisp look.
– Holds moisture: Takes longer to dry and can feel damp when sweaty.

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

50/50 Blend: The Best of Both Worlds

Pros:
– Durable and long-lasting: Resists pilling and holds its shape better than 100% cotton.
– Less shrinkage: Blended fibers reduce shrinking during washes.
– Soft with a slight stretch: Offers comfort and a bit more flexibility.
– Affordable: Often priced between cotton and tri-blends.

Cons:
– Slightly less breathable: Polyester content can trap heat.
– Prints may appear less vibrant: Ink doesn’t absorb as deeply, which can dull colors slightly.
– Less eco-friendly: Contains synthetic fibers that don’t biodegrade easily.

Best For: Active wear, workwear, team uniforms, and budget-conscious projects where durability matters.

Tri-Blends: Softness, Drape, and Style

Pros:
– Luxuriously soft: Typically made from a blend of cotton, polyester, and rayon (often 50/25/25).
– Excellent drape: Flattering fit with a smooth, slightly silky texture.
– Minimal shrinkage: Holds shape well after repeated washes.
– Fade-resistant: Prints tend to last longer due to fiber stability.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Less breathable: Rayon and polyester can reduce air circulation.
– Delicate care needed: May require gentler washing to maintain softness.
– Not ideal for heavy ink coverage: Thin fabric may show print-through on the back.

Best For: Fashion-forward apparel, boutique brands, women’s cuts, and vintage-style designs.

How to Choose the Right Fabric

Consider these factors when deciding:
– Intended use: Is it for everyday wear, athletic events, or fashion statements?
– Target audience: Prioritize comfort, durability, or style?
– Print design: Bold graphics favor cotton; subtle, vintage looks suit tri-blends.
– Budget: Cotton is usually cheapest, tri-blends the most premium.
– Care instructions: Will users machine-wash frequently?

Ultimately, the best fabric depends on your priorities. Whether you value softness, durability, or a stylish drape, there’s a perfect blend for your custom t-shirt project.

How to Get the Best Price on Custom T-Shirts (Including Bulk Discounts and Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To ensure you get the best price without sacrificing quality, follow these expert tips on bulk quantity breaks and artwork optimization.

Take Advantage of Bulk Quantity Breaks

Most custom t-shirt suppliers offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost. Here’s how to maximize savings:

• Order in Larger Quantities: Typical quantity breaks occur at 50, 100, 250, and 500+ units. Jumping to the next tier (e.g., from 75 to 100 shirts) can significantly reduce your cost per shirt.
• Consolidate Orders: If multiple departments or teams need shirts, combine orders to reach higher quantity tiers.
• Plan Ahead: Forecast future needs and order in advance to lock in lower pricing.
• Compare Vendors: Different suppliers have different break points and pricing structures. Use online quote tools to compare prices across companies.

Choose the Right Printing Method

The printing technique affects both cost and quality. Select the most cost-effective method for your design:

• Screen Printing: Best for large orders with simple designs (1–4 colors). Cost per shirt drops significantly with volume.
• DTG (Direct-to-Garment): Ideal for complex, full-color designs on smaller batches. Less cost-efficient for bulk orders.
• Heat Transfer or Vinyl: Good for small runs or detailed logos, but less durable and not ideal for large quantities.

Optimize Your Artwork to Reduce Costs

Your design can impact production cost. Follow these artwork tips to save money:

• Simplify Your Design: Fewer colors and less detail mean lower screen printing costs. Stick to 1–3 colors when possible.
• Use Vector Files: Provide artwork in vector format (AI, EPS, or SVG) to avoid redraw fees and ensure crisp printing.
• Avoid All-Over Prints: Full-shirt designs require more ink and time, increasing costs. Focus on chest, back, or sleeve prints.
• Standard Print Sizes: Oversized or custom print areas may incur extra charges. Stick to standard sizes (8″–12″ wide).

Choose Cost-Effective Shirt Styles and Colors

Basic, popular shirt styles and colors are usually cheaper:

• Opt for Common Colors: White, black, navy, and gray t-shirts are typically less expensive than specialty colors.
• Select Mid-Range Brands: Premium brands (e.g., Bella+Canvas) cost more. Balance quality and budget with reliable mid-tier options.
• Stick to One Style: Mixing shirt styles or brands can increase setup and fulfillment costs.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote:

• Request Quotes from 3–5 Suppliers: Use online tools or contact vendors directly.
• Ask About Promotions: Many companies offer seasonal discounts, first-time customer deals, or free shipping.
• Negotiate: For large orders, ask if they can match a competitor’s price or offer additional perks (e.g., free mockups or revisions).

Final Tips for Maximum Savings

• Order All at Once: Splitting orders increases setup fees.
• Approve a Physical Sample: Avoid costly reprints by approving a printed sample first.
• Watch for Hidden Fees: Confirm if taxes, shipping, setup, or art fees are included.

By leveraging bulk quantity breaks, optimizing your artwork, and choosing the right materials and vendor, you can get high-quality custom t-shirts at the best possible price.