Comparison of Custom T-Shirt Printing Methods

Guide to Choosing Fabrics for Customized T-Shirts: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

Choosing the right fabric for your custom t-shirts is essential for comfort, durability, and how well your design turns out. The three most popular options—100% cotton, 50/50 blend, and tri-blends—each offer distinct benefits and trade-offs. Here’s a breakdown to help you decide which is best for your needs.

100% Cotton T-Shirts

Pros:
– Soft and Breathable: Pure cotton is naturally soft, absorbs moisture well, and keeps you cool—ideal for warm weather or active wear.
– Eco-Friendly Option: Cotton is biodegradable and often preferred by environmentally conscious consumers.
– Great for Printing: Holds screen printing and direct-to-garment (DTG) inks well, producing vibrant, crisp designs.
– Classic Feel: Offers that traditional, familiar t-shirt texture many people love.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk; washing in hot water can cause significant shrinkage.
– Less Durable: Can wear out faster and may pill over time with frequent washing.
– Wrinkles Easily: Requires ironing for a polished look.

Best For: Everyday wear, promotional giveaways, eco-focused brands, or when a natural fabric feel is a priority.

50/50 Blend T-Shirts (50% Cotton, 50% Polyester)

Pros:
– Durable and Long-Lasting: The polyester adds strength, reducing wear and tear.
– Resists Shrinking: Much more stable in the wash than 100% cotton.
– Less Wrinkling: Holds its shape well and requires less ironing.
– Affordable: Typically priced between 100% cotton and tri-blends, offering a good balance.

Cons:
– Less Breathable: Polyester doesn’t breathe as well, which can make shirts feel warmer.
– Slightly Less Soft: May feel coarser than 100% cotton or tri-blends, especially in lower thread counts.
– Pilling Risk: Can develop small fabric balls over time, particularly with friction.

Best For: Budget-friendly custom apparel, workwear, school events, or high-use garments where durability matters.

Tri-Blend T-Shirts (Usually 50% Polyester, 25% Cotton, 25% Rayon)

Pros:
– Ultra-Soft and Silky: Blends create a luxurious, vintage-like drape that feels premium against the skin.
– Excellent Drape: Flatters the body and resists clinging, great for fashion-forward designs.
– Wrinkle-Resistant: Maintains a smooth look with minimal care.
– Color Retention: Holds dye and prints beautifully, often with a slightly heathered, retro appearance.

Cons:
– Higher Price: Typically the most expensive of the three options.
– Less Absorbent: Rayon and polyester don’t absorb moisture as well as cotton.
– Sensitivity to Heat: Can be damaged by high heat during washing or drying—requires gentle care.

Best For: Premium custom tees, fashion brands, boutique apparel, or when a soft, stylish look is key.

Final Tips for Choosing

• Consider the Use: Is it for daily wear, gifts, or performance? Prioritize comfort, durability, or cost accordingly.
• Think About Care: Will customers machine-wash frequently? Blends generally require less maintenance.
• Match the Design: Vibrant screen prints work well on cotton and 50/50 blends. Soft, vintage-style prints shine on tri-blends.
• Know Your Audience: Younger demographics may prefer tri-blends, while eco-conscious buyers may choose 100% cotton.

By understanding the strengths of each fabric, you can select the ideal t-shirt material that aligns with your brand, budget, and customer expectations.

How to Get the Best Price for Customized 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. However, to truly get the best price, it’s essential to understand bulk pricing structures and how to optimize your design and order process. Here’s a comprehensive guide to help you save money without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printers and custom apparel suppliers offer tiered pricing based on order volume—known as quantity breaks. The more shirts you order, the lower the per-unit cost.

• Know the Thresholds: Common quantity breaks include 25, 50, 75, 100, 250, and 500 units. For example, the price per shirt might drop significantly when moving from 49 to 50 units.
• Order Strategically: Aim for the next pricing tier (e.g., 100 instead of 75) if you anticipate future needs. Leftover shirts are often cheaper than a second small order.
• Mix Sizes, Not Styles: You can usually mix sizes (S, M, L, XL) within the same style and design without affecting the bulk price. Avoid mixing different shirt brands or styles, as this may reset pricing tiers.

Choose the Right Printing Method

The printing technique impacts both cost and quality. Select one that fits your design complexity and budget.

• Screen Printing: Best for large orders (50+ units) with simple, bold designs. Low cost per unit after setup fees are spread across many shirts.
• Direct-to-Garment (DTG): Ideal for detailed or full-color designs, but more expensive per unit. Cost-effective only for very small runs or when designs vary greatly.
• Heat Transfer/Vinyl: Good for small orders or specialty finishes (e.g., glitter), but less durable and pricier per piece at scale.

Simplify Your Design to Reduce Costs

Complex artwork increases production time and expense. Streamline your design to lower your overall cost.

• Limit Colors: Each additional color in screen printing requires a separate screen and setup fee. Stick to 1–3 colors for maximum savings.
• Use Vector Art: Provide artwork in vector format (e.g., .AI, .EPS, .SVG) to avoid extra fees for design cleanup or redrawing.
• Avoid Gradients and Photo Effects: These often require simulated process printing or DTG, which are costlier than standard screen printing.

Prepare Print-Ready Artwork

Suppliers may charge extra to fix poorly formatted artwork. Save money with professional preparation.

• High Resolution: For raster images, use at least 300 DPI at the actual print size.
• Correct File Types: Provide vector files for logos and text. Use PNG or TIFF for detailed images if DTG is used.
• Include Bleed and Safe Zones: Extend background elements 1/8 inch beyond the print area and keep critical text/logo elements 1/4 inch from edges.

Negotiate and Compare Quotes

Never accept the first quote. Multiple bids increase your leverage.

• Request Quotes from 3–5 Suppliers: Compare not just price, but also minimums, turnaround time, and included services (e.g., free design help, free shipping).
• Ask About Discounts: Inquire about discounts for nonprofits, schools, or repeat customers. Some suppliers offer seasonal promotions.
• Bundle Services: If ordering other promo items (hats, bags), ask for a package discount.

Consider Shirt Quality and Brand

Not all blanks are created equal—and price varies widely.

• Mid-Grade Cotton is Often the Sweet Spot: Avoid the cheapest blanks (poor fit/printability) and ultra-premium brands (overpriced for bulk). Brands like Gildan, Bella+Canvas, and Next Level offer good quality at competitive prices.
• Stick to One Color: Ordering all shirts in the same color reduces setup and inventory costs.

Plan Ahead to Avoid Rush Fees

Rush orders can increase costs by 25–50%.

• Order Early: Place your order at least 2–3 weeks before you need the shirts.
• Confirm Deadlines Upfront: Ensure production and shipping timelines align with your event or launch date.

By leveraging bulk quantity breaks, simplifying your design, preparing proper artwork, and shopping wisely, you can significantly reduce the cost of your custom t-shirts—without compromising on professionalism or impact.