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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing T-Shirt Fabrics

When customizing t-shirts for your brand, event, or personal use, the fabric you choose plays a major role in comfort, durability, appearance, and overall satisfaction. Here’s a breakdown of the three most popular fabric options to help you make the best choice.

100% Cotton

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warm weather, due to natural breathability.
– Eco-Friendly Option: Biodegradable and made from a renewable resource, appealing to environmentally conscious buyers.
– Great for Printing: Provides a smooth, absorbent surface ideal for vibrant screen printing and detailed designs.
– Classic Feel: Delivers the traditional soft, casual t-shirt experience many people love.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable: Can wear out faster with frequent washing and may pill over time.
– Wrinkles Easily: Tends to wrinkle more than blended fabrics, requiring more care.

Best For: Everyday casual wear, eco-conscious brands, and designs that require crisp, bold print results.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Improved Durability: Polyester adds strength, making the shirt more resistant to wear and tear.
– Less Shrinking: More stable than 100% cotton—retains its shape and size after multiple washes.
– Wrinkle-Resistant: Holds up better during daily use and travel with minimal ironing.
– Affordable: Often priced between 100% cotton and tri-blends, offering a balanced cost-performance ratio.

Cons:
– Slightly Less Soft: Can feel a bit rougher than 100% cotton or tri-blends, especially in lower-quality versions.
– Less Breathable: Polyester reduces breathability, which may feel warmer in hot climates.
– Prone to Pilling: Over time, friction can cause small fabric balls (pills), especially in high-rub areas.

Best For: Workwear, promotional giveaways, and budget-friendly custom shirts that need to withstand regular use.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Pros:
– Ultra-Soft Hand Feel: Combines the softness of cotton with the smooth drape of rayon and durability of polyester for a luxurious feel.
– Excellent Drape: Flattering fit that drapes well on the body, great for fashion-forward designs.
– Moisture-Wicking: Polyester helps pull moisture away, improving comfort during activity.
– Minimal Shrinkage: Highly stable through washes and heat.

Cons:
– Higher Cost: Typically more expensive than cotton or 50/50 blends.
– Less Structured: The soft drape may not hold structured designs as crisply as stiffer fabrics.
– Delicate Printing Needs: Rayon can be more sensitive during printing—requires experienced decorators to avoid cracking or fading.

Best For: Premium apparel, fashion brands, women’s cuts, and soft, vintage-style tees with a modern feel.

Final Tips for Choosing

• Consider the Use: Will it be worn daily, for sports, or as a keepsake? Match fabric to function.
• Think About Climate: Cotton breathes best in heat; blends offer versatility.
• Prioritize Print Quality: 100% cotton and tri-blends offer excellent print results, but with different textures.
• Know Your Audience: A luxury brand may prefer tri-blends, while a corporate giveaway might go for 50/50 durability.

By understanding the strengths and trade-offs of each fabric, you can confidently select the perfect material for your custom t-shirts—balancing comfort, cost, and long-term wear.

How to Get the Best Price for Customized T-Shirts (Bulk Quantity Breaks & 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 high-quality results, understanding bulk pricing strategies and preparing your artwork correctly is essential. Here’s how to get the best value.

Leverage Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing—larger orders cost less per unit. Take full advantage of these quantity breaks:

• Know the Common Break Points: Typical quantity tiers are 12, 24, 36, 48, 72, 100, 250, and 500+ units. Ordering just above a break point (e.g., 100 instead of 72) often results in significant per-unit savings.
• Consolidate Orders: Combine needs across departments, events, or teams to reach higher quantity tiers.
• Consider Future Needs: If you anticipate future t-shirt needs, ordering more now can save money—even if you don’t use all shirts immediately.

Choose the Right T-Shirt Style and Brand

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

• Select Mid-Range Blanks: High-end brands (e.g., Gildan Softstyle, Bella+Canvas) offer better feel and durability than ultra-cheap options, but are more affordable than premium fashion labels.
• Stick to One Style: Ordering all shirts in the same style, color, and brand reduces setup and processing costs.
• Buy in Bulk from Suppliers: If ordering very large quantities (500+), consider purchasing blank shirts in bulk separately and using a print-only service.

Optimize Your Artwork for Cost Efficiency

The complexity of your design directly impacts printing costs.

• Limit Print Colors: Each additional ink color increases setup time and cost. Stick to 1–3 colors whenever possible.
• Use Vector Art: Provide artwork in vector format (e.g., AI, EPS, SVG) for crisp, scalable prints. Avoid low-resolution JPEGs or PNGs.
• Simplify Your Design: Minimize fine details and gradients, which are harder and more expensive to reproduce in screen printing.
• Standard Print Locations: Chest prints are cheaper than full back or sleeve designs. Stick to one print location unless essential.
• Avoid Photo-Realistic Prints: These often require simulated process printing or DTG (direct-to-garment), which is costlier than traditional screen printing.

Get Multiple Quotes and Negotiate

• Compare at Least 3 Suppliers: Use online quote tools or request custom quotes from local and national vendors.
• Ask About Hidden Fees: Confirm whether setup, screen, and art fees are included. Some vendors waive fees for large orders.
• Negotiate for Repeat Orders: If planning future orders, ask about loyalty discounts or contracts with volume pricing.

Time Your Order Wisely

• Avoid Rush Fees: Place your order well in advance of your event or deadline to avoid expedited production charges.
• Look for Seasonal Promotions: Some printers offer discounts during slower months (e.g., winter for summer events).

By combining smart bulk ordering, efficient artwork, and strategic vendor selection, you can achieve professional-quality custom t-shirts at the lowest possible price.