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

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

When customizing t-shirts online, the fabric you choose dramatically impacts comfort, durability, drape, and how your design turns out. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends is essential for making the right choice for your project. Here’s a breakdown to help you decide.

What is 100% Cotton?

100% cotton t-shirts are made entirely from natural cotton fibers. They are the classic choice for custom apparel and are known for their softness, breathability, and natural feel.

Pros:
– Soft and Comfortable: Feels great against the skin, especially after a few washes.
– Breathable: Ideal for warm weather or active wear due to excellent moisture absorption.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.
– Great for Printing: Provides a smooth, consistent surface for screen printing and DTG (direct-to-garment) printing.

Cons:
– Prone to Shrinking: May shrink if not pre-shrunk, especially when washed in hot water.
– Wrinkles Easily: Requires ironing or steaming to look crisp.
– Less Durable Over Time: Can wear out faster than blended fabrics, especially with frequent washing.
– May Fade: Colors may fade more over time compared to synthetic blends.

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

What is a 50/50 Blend?

A 50/50 blend typically combines 50% cotton and 50% polyester. This hybrid fabric offers a balance of natural and synthetic fibers, making it a popular mid-range option.

Pros:
– Durable and Resilient: Polyester adds strength, reducing pilling and extending the shirt’s lifespan.
– Resists Shrinkage: Less likely to shrink than 100% cotton.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Affordable: Often more budget-friendly than premium cotton or tri-blend options.

Cons:
– Less Breathable: Polyester doesn’t breathe as well as cotton, which can make it feel warmer.
– Slight Sheen: May have a slightly synthetic look compared to pure cotton.
– Not as Soft Initially: Can feel a bit rougher than 100% cotton, though it softens over time.

Best For: High-use environments (like employee uniforms), budget-conscious orders, and garments that need frequent washing.

What is a Tri-blend?

Tri-blend fabrics usually consist of a mix of cotton, polyester, and rayon (often around 50% polyester, 25% cotton, 25% rayon). This combination creates a uniquely soft and lightweight fabric with a vintage feel.

Pros:
– Ultra-Soft and Silky: Offers a luxurious, smooth texture that feels premium.
– Excellent Drape: Flows nicely on the body, giving a more fitted, modern look.
– Vintage Aesthetic: Has a slightly heathered, worn-in appearance that ages well.
– Lightweight and Comfortable: Ideal for layering or warm climates.

Cons:
– More Expensive: Typically the priciest of the three options.
– Less Durable: Can be more delicate and prone to snagging or thinning over time.
– Special Care Required: May need gentle washing to maintain quality.
– Print Results Vary: The heathered texture can affect print opacity, especially with lighter inks.

Best For: Fashion-forward apparel, boutique brands, gift items, and designs aiming for a retro or vintage vibe.

How to Choose the Right Fabric for Your Custom T-Shirt

Consider these factors when deciding:

• Intended Use: Will the shirts be worn daily, given as gifts, or used for events? Durability matters for frequent wear.
• Climate: Choose breathable cotton or tri-blends for warm areas; 50/50 blends work well year-round.
• Budget: 50/50 blends offer value, while tri-blends are a premium choice.
• Design Style: Bold prints work well on cotton and 50/50s; vintage designs shine on tri-blends.
• Comfort Priority: If softness is key, tri-blends lead; for natural feel, go cotton.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently select the perfect fabric for your custom t-shirts—ensuring both satisfaction and style.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. However, to get the best price, you need to understand how pricing works and how to optimize your order. Here’s a step-by-step guide with key insights on bulk quantity breaks and artwork best practices.

Leverage Bulk Quantity Breaks

Most online print shops offer tiered pricing—larger orders cost less per unit. To maximize savings:

• Order in Larger Quantities: Prices drop significantly at thresholds like 50, 100, or 250 units. For example, 50 shirts might cost $12 each, while 100 could drop to $8 each.
• Plan Ahead: If you’re unsure about future needs, it’s often cheaper to order more now and store extras than to reorder later.
• Combine Orders: Coordinate with other departments, teams, or events to consolidate orders and hit higher quantity tiers.
• Compare Multiple Suppliers: Use quote tools from vendors like Printful, Custom Ink, or Printify to compare bulk pricing across platforms.

Choose Cost-Effective Shirt Options

Not all t-shirts are created equal—and price varies widely based on brand, fabric, and cut.

• Opt for Basic Styles: Generic or value-priced brands (e.g., Gildan, Hanes) are cheaper than premium ones (e.g., Bella+Canvas).
• Stick to Standard Colors: White and black typically cost less than specialty colors.
• Minimize Shirt Variety: Ordering all the same style and color reduces setup and printing costs.

Optimize Your Artwork for Lower Printing Costs

The design plays a major role in final pricing. Simple designs = lower costs.

• Limit Print Colors: Each additional color increases setup fees, especially with screen printing. Stick to 1–2 colors when possible.
• Use Vector Art: Provide high-resolution vector files (AI, EPS, SVG) to avoid reformatting fees and ensure crisp prints.
• Simplify the Design: Avoid complex gradients or photorealistic images, which may require pricier printing methods like DTG (direct-to-garment).
• Stick to One Print Location: Printing on the front only is cheaper than front + back or sleeves.

Choose the Right Printing Method

Different techniques have different cost structures:

• Screen Printing: Best for large bulk orders with simple designs. Low per-unit cost after setup.
• DTG (Direct-to-Garment): Great for full-color or detailed artwork, but more expensive per shirt for large runs.
• Heat Transfer or Vinyl: Cost-effective for small batches or text-heavy designs, but less durable.

Get Quotes and Negotiate

• Use Online Quote Tools: Most suppliers offer instant bulk pricing calculators.
• Ask for Discounts: Some vendors offer seasonal sales, nonprofit discounts, or promo codes.
• Consider Local vs. Online: While online platforms are convenient, local printers may offer competitive pricing and faster turnaround.

Final Tips for the Best Deal

• Proof Before Printing: Request a digital or physical sample to avoid costly reprints.
• Watch for Hidden Fees: Check for charges like setup, shipping, or art correction.
• Time Your Order: Avoid peak seasons (e.g., back-to-school, holidays) when demand—and prices—rise.

By combining smart bulk ordering, simple designs, and strategic vendor selection, you can significantly reduce the cost of custom t-shirts while maintaining quality.