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 a Custom T-Shirt

When designing your own custom T-shirt, the fabric you choose plays a huge role in comfort, durability, appearance, and how your design looks and feels. Three of the most popular options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s a breakdown to help you pick the perfect one for your project.

100% Cotton: The Classic Choice

Pros:
– Soft and Breathable: Natural fibers make it comfortable to wear, especially in warm weather.
– Great for Printing: Absorbs ink well, resulting in vibrant, crisp prints—ideal for detailed designs.
– Eco-Friendly Option: Biodegradable and often available in organic versions.
– Timeless Feel: Offers the traditional T-shirt hand feel that many people love.

Cons:
– Prone to Shrinkage: Can shrink up to 5–7% if not pre-shrunk, especially when washed in hot water.
– Less Durable: More likely to wear out, pill, or fade over time with frequent washing.
– Wrinkles Easily: Requires ironing or steaming to look neat.
– Absorbs Moisture: Holds sweat and odors more than synthetic blends.

Best For: Casual wear, vintage-style tees, eco-conscious brands, and designs that benefit from a soft, natural hand feel.

50/50 Blend: The Best of Both Worlds

Pros:
– Balanced Performance: Combines the softness of cotton with the durability and resilience of polyester.
– Reduced Shrinkage: Holds its shape better than 100% cotton after multiple washes.
– Affordable: Often priced lower than tri-blends or premium cottons.
– Good Print Surface: Works well with screen printing and DTG (direct-to-garment), offering bright colors with less bleeding.

Cons:
– Less Breathable: Polyester content can make it warmer to wear in hot climates.
– Slight Sheen: May have a subtle synthetic look compared to the matte finish of pure cotton.
– Can Pill Over Time: Especially with lower-quality fabrics or frequent friction.

Best For: Budget-friendly custom shirts, promotional wear, workwear, and everyday tees that need to hold up over time.

Tri-Blends: The Premium, Fashion-Forward Option

Pros:
– Ultra-Soft and Lightweight: Typically made from a mix of cotton, polyester, and rayon (e.g., 50% polyester, 25% cotton, 25% rayon), resulting in a buttery-soft, draping feel.
– Excellent Drape: Flatters the body and gives a more modern, fitted look.
– Minimal Shrinkage: Holds shape well and resists wrinkling.
– Vintage Aesthetic: Often used for heathered or mottled colors, giving shirts a trendy, lived-in look.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends.
– Less Durable for Heavy Use: Softer fibers can be more prone to snagging or thinning with heavy wear.
– Printing Challenges: Requires careful handling during printing to avoid ink absorption issues or design cracking—DTG often works best.

Best For: Fashion-focused brands, boutique apparel, gifts, and custom shirts where comfort and style are top priorities.

Final Tips for Choosing

• Consider the Use: Is it for a concert, a corporate promo, or a gift? Durability matters for frequent wear.
• Think About Climate: Cotton and tri-blends breathe better; 50/50 blends offer more moisture-wicking.
• Match Fabric to Design: Bold graphics often pop on 100% cotton or 50/50s, while subtle, vintage designs shine on tri-blends.
• Check Care Instructions: Always recommend washing inside out in cold water to preserve color and fabric.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can make an informed choice that ensures your custom T-shirt looks great, feels comfortable, and lasts as long as possible.

How to Get the Best Price When Customizing Your Own T-Shirts (Bulk Discounts & 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 without sacrificing quality, you’ll need to plan strategically. Here’s how to save money through bulk quantity breaks and optimize your design process for lower costs.

Leverage Bulk Quantity Breaks

Most screen printing and apparel suppliers offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost. Here’s how to take full advantage:

• Know the Break Points: Suppliers often have quantity tiers like 25, 50, 100, 250, and 500 units. Ordering just above a break point (e.g., 101 instead of 99) can significantly reduce your price per shirt.

• Consolidate Orders: If possible, combine multiple small needs (e.g., events, departments, or teams) into one larger order to hit a higher discount tier.

• Choose Standard Sizes and Colors: Custom colors or uncommon sizes can increase production costs. Stick to popular colors (like black, white, or navy) and standard unisex or athletic fits to keep prices low.

• Limit Color Variations: Ordering the same design across different shirt colors still counts toward your bulk discount. Avoid splitting orders into too many unique designs or colorways.

Optimize Your Artwork to Reduce Printing Costs

The complexity of your design directly affects printing costs. Simple designs save money and speed up production.

• Use Fewer Ink Colors: Each additional color in screen printing requires a separate screen and setup fee. Stick to 1–3 colors to minimize cost.

• Simplify the Design: Avoid fine details, gradients, or photographic elements that require advanced (and expensive) printing methods like DTG (Direct-to-Garment). Opt for bold, clean graphics.

• Vector Files Are Best: Supply artwork in vector format (e.g., .AI, .EPS, or .SVG) to ensure crisp printing at any size. High-resolution PDFs or PNGs (300 DPI) are acceptable but less ideal.

• Stick to One Print Location: Printing on just the front or back is cheaper than multi-location prints (e.g., front + sleeve). Choose the most visible location for impact.

• Avoid All-Over Prints: Full-shirt or sleeve-to-sleeve designs dramatically increase ink use and labor. Focus your design on a single area like the chest or back.

Compare Suppliers and Negotiate

Don’t settle for the first quote. Get estimates from multiple printers—local shops, online services (like Custom Ink, Printful, or RushOrderTees), and wholesale suppliers.

• Ask About Setup Fees: Some vendors waive or reduce screen setup fees for bulk orders.
• Inquire About Blank Garment Options: Choosing mid-tier blank shirts (like Gildan Heavy Cotton or Bella+Canvas) balances quality and cost.
• Request Samples: Order a sample first to evaluate print quality and fabric feel before committing to large quantities.

Plan Ahead to Avoid Rush Fees

Rush processing can add 20–50% to your order cost. Place your order well in advance—ideally 2–4 weeks before you need the shirts—to avoid expedited charges.

By using bulk quantity breaks wisely and simplifying your artwork, you can create high-impact custom t-shirts at a fraction of the cost. Smart planning and clear communication with your supplier are key to getting the best value.