Screen Printing vs. DTG vs. Heat Transfer: T-Shirt Customization Comparison

| Feature | Screen Printing | Direct-to-Garment (DTG) | Heat Transfer |
|——————————-|———————————————–|————————————————–|———————————————–|
| Best For | Large orders, simple designs, vibrant colors | Small orders, detailed/full-color designs | Small batches, quick turnaround, on-demand |
| Setup Time & Cost | High setup (screens, films), low per-unit cost| Minimal setup, higher per-unit cost | Minimal setup, moderate per-unit cost |
| Print Quality | Excellent for solid colors, limited detail | High detail, photo-quality, smooth gradients | Good to excellent (depends on method/material)|
| Durability | Very durable, long-lasting print | Good, but may fade over time with washing | Varies; sublimation very durable, vinyl peels |
| Fabric Compatibility | Best on cotton or cotton blends | Works on cotton, cotton blends, some synthetics | Works on cotton, polyester, blends (depends) |
| Color Limitations | Each color requires separate screen | Unlimited colors, no extra cost per color | Unlimited colors (inkjet/dye-sublimation) |
| Cost Efficiency (Volume) | Most cost-effective for large runs (50+) | Cost-effective for 1–50 units | Cost-effective for 1–20 units |
| Turnaround Time | Slower (due to setup) | Fast for small orders | Very fast (especially with pre-made transfers)|
| Design Flexibility | Low (design changes = new screens) | High (easy to change designs) | Very high (ideal for one-offs and prototypes) |
| Texture/Feel | Thicker, plasticky feel (especially plastisol)| Soft, almost no feel (water-based inks) | Can be stiff (vinyl) or soft (dye-sublimation)|
| Eco-Friendliness | Moderate (plastisol inks less eco-friendly) | Higher (water-based inks, low waste) | Varies (dye-sublimation uses energy, vinyl waste) |
| Ideal Use Cases | Bulk merch, sports teams, logos, events | Art prints, photos, detailed artwork, startups | Custom names/numbers, small gifts, prototypes |

Summary:

• Screen Printing excels in durability and cost for large, simple designs.
• DTG is perfect for intricate, colorful designs in small quantities with soft feel.
• Heat Transfer offers speed and flexibility for one-offs and small runs, with varying durability.

Guide to Choosing Fabrics for Customized T-Shirts: 100% Cotton vs. Tri-Blends vs. Polyester

When designing custom t-shirts, one of the most important decisions you’ll make is choosing the right fabric. The material impacts comfort, durability, print quality, and overall feel. Here’s a breakdown of the three most popular fabric options—100% Cotton, Tri-blends, and Polyester—to help you make the best choice for your needs.

100% Cotton

Pros:
– Soft and Breathable: 100% cotton is naturally soft, especially after a few washes, and allows air to circulate, making it ideal for warm weather and everyday wear.
– Comfortable Against Skin: Hypoallergenic and gentle, cotton is a great choice for sensitive skin.
– Eco-Friendly Option: Biodegradable and often sourced from sustainable farming (especially with organic cotton).
– Excellent for Printing: Absorbs ink well, making it ideal for screen printing and direct-to-garment (DTG) printing with vibrant, detailed results.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster than synthetic blends, especially with frequent washing.
– Wrinkles Easily: Tends to crease and lose shape over time.
– Absorbs Moisture: While breathable, it also holds onto sweat, which may be less ideal for athletic use.

Best For: Casual wear, promotional tees, fashion-focused designs, and eco-conscious brands.

Tri-Blends (Typically Cotton, Polyester, and Rayon)

Pros:
– Luxurious Feel: Combines the softness of cotton, durability of polyester, and drape of rayon for a smooth, silky texture.
– Excellent Drape: Flattering fit with a slightly more fitted, vintage look.
– Color Retention: Holds dye well and resists fading over time.
– Lightweight and Comfortable: Great for layering or warmer climates.

Cons:
– More Expensive: Typically higher cost than 100% cotton or polyester.
– Less Durable Under Stress: May pill or wear faster with heavy use or frequent washing.
– Slight Shrinkage: Can shrink slightly, though usually less than 100% cotton.
– Printing Considerations: Works well with DTG, but may require adjustments for screen printing due to fabric stretch.

Best For: Fashion-forward apparel, boutique brands, women’s tees, and styles where softness and drape are priorities.

Polyester

Pros:
– Highly Durable: Resistant to shrinking, stretching, and wrinkling. Ideal for long-term use.
– Moisture-Wicking: Pulls sweat away from the body, keeping you dry—perfect for activewear.
– Quick-Drying: Excellent for sportswear, outdoor events, or humid climates.
– Retains Shape and Color: Maintains its form and resists fading, even after multiple washes.

Cons:
– Less Breathable: Can feel hot or clammy in warm weather due to low air permeability.
– Static and Odor Retention: May hold onto odors and generate static electricity.
– Texture: Some find it less soft or “plasticky” compared to cotton or tri-blends.
– Environmental Impact: Made from petroleum; not biodegradable (though recycled polyester is a greener option).

Best For: Performance wear, athletic teams, outdoor events, sublimation printing (especially full-coverage designs), and high-durability needs.

How to Choose the Right Fabric

• For Everyday Comfort & Classic Look: Choose 100% Cotton.
• For Softness, Style, and a Premium Feel: Go with Tri-Blend.
• For Performance, Durability, and Moisture Control: Select Polyester.

Consider your audience, the intended use of the shirt, and your printing method when making your final decision. Each fabric has unique strengths—matching the right material to your project ensures a high-quality, satisfying result.

How to Get the Best Price for Customized T-Shirts (Bulk Discounts & Artwork Tips)

Ordering customized t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To maximize savings and ensure professional results, follow these strategies for securing the best price and preparing your artwork efficiently.

Leverage Bulk Discounts Effectively

One of the biggest factors in lowering your per-unit cost is ordering in larger quantities. Most screen printing and embroidery companies offer tiered pricing, meaning the more you order, the less each shirt costs.

• Order in Standard Volume Tiers: Aim for common bulk quantities like 24, 48, 72, or 144 units. Suppliers often have preset pricing at these levels, and going even slightly above a tier can trigger a significant price break.
• Consolidate Designs When Possible: Each unique design setup incurs a fee. If you need multiple shirt designs, consider using the same artwork with different colors or minor text variations to reduce setup costs.
• Choose Simpler Printing Methods: Screen printing is generally cheaper for large runs with fewer colors. Avoid specialty inks (like metallic or puff) unless essential—they increase cost and setup time.
• Compare Multiple Vendors: Get quotes from at least 3–5 reputable suppliers. Many online printers offer instant quotes, making it easy to compare pricing, shipping, and minimums.
• Negotiate for Repeat Orders: If you anticipate future orders, mention it to the vendor. They may offer a discount or loyalty program for long-term business.

Optimize Artwork Preparation to Save Money

Proper artwork setup prevents production delays and extra fees. Follow these tips to ensure your design is print-ready and cost-efficient.

• Use Vector Files (EPS, AI, or SVG): Vector graphics scale infinitely without losing quality, making them ideal for printing. Most professional printers prefer vector artwork for clean, crisp results.
• Keep Designs Simple: Limit the number of colors in your design. Each additional color requires a separate screen in screen printing, increasing setup costs. Stick to 1–3 colors when possible.
• Provide High-Resolution Raster Files if Needed: If using a raster image (like a logo), ensure it’s at least 300 DPI and the correct print size. Low-resolution images may require costly redrawing.
• Outline All Fonts: Convert text to outlines (or paths) in your design software to prevent font substitution issues during printing.
• Specify Pantone (PMS) Colors: If brand color accuracy is crucial, provide Pantone color codes. This avoids guesswork and ensures consistency across batches.
• Submit a Mockup: Include a digital mockup showing exactly where the design should appear (e.g., center chest, left pocket, full back). This reduces errors and reprints.

By combining smart bulk ordering with professional artwork preparation, you can significantly reduce costs while achieving high-quality custom t-shirts for your needs.