Comparison Table: 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

Choosing the right fabric is crucial when designing your own custom t-shirts. The material affects comfort, durability, print quality, drape, and overall feel. Here’s a breakdown of the three most popular options to help you make the best choice for your project.

100% Cotton

Pros:
– Soft and Breathable: Natural fibers make cotton comfortable to wear, especially in warm weather.
– Eco-Friendly: Biodegradable and often available in organic varieties.
– Great for Printing: Holds screen prints and DTG (direct-to-garment) inks well, producing vibrant, crisp designs.
– Classic Feel: Offers a traditional t-shirt experience that many people love.

Cons:
– Prone to Shrinking: Can shrink if not pre-shrunk or washed improperly.
– Less Durable: Tends to wear out faster and may pill over time.
– Wrinkles Easily: Requires ironing for a crisp look.
– Absorbs Moisture: While breathable, it holds sweat and takes longer to dry.

Best For: Casual wear, promotional giveaways, eco-conscious brands, and designs requiring bold, detailed prints.

50/50 Cotton-Polyester Blend

Pros:
– Durable and Long-Lasting: Polyester adds strength and resistance to wear and tear.
– Less Shrinking: More stable than 100% cotton when washed.
– Affordable: Often less expensive than tri-blends or premium cottons.
– Good Print Surface: Works well with screen printing, especially for standard designs.

Cons:
– Less Breathable: Polyester can trap heat, making it less comfortable in hot climates.
– Less Soft: Can feel slightly rougher or stiffer than cotton or tri-blends.
– Pilling Potential: May develop small fabric pills over time with friction.
– Not as Eco-Friendly: Polyester is a synthetic fiber derived from petroleum.

Best For: Budget-friendly bulk orders, workwear, events, and designs that need a durable, no-fuss fabric.

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

Pros:
– Ultra-Soft and Smooth: Feels luxurious and drapes beautifully—often described as “buttery soft.”
– Excellent Drape: Flatters the body and moves well, ideal for fitted styles.
– Vintage Look: Gives prints a slightly faded, retro appearance that many find appealing.
– Resists Shrinking and Wrinkling: More stable than 100% cotton.

Cons:
– Higher Cost: Usually the most expensive of the three options.
– Less Breathable Than Cotton: Rayon and polyester don’t breathe as well as pure cotton.
– Delicate Prints: May not hold up as well to heavy ink coverage; best for lighter, softer designs.
– Care Required: May need gentler washing to maintain softness and prevent pilling.

Best For: Fashion-forward tees, boutique brands, women’s cuts, and designs with a vintage or artistic aesthetic.

Final Tips for Choosing

• Consider Your Audience: Are they looking for comfort, durability, or style?
• Think About Use: Is it for daily wear, events, or promotional giveaways?
• Evaluate Print Design: Detailed artwork may need 100% cotton or a 50/50 blend, while soft graphics shine on tri-blends.
• Budget Matters: Tri-blends offer premium feel but come at a higher price.
• Test First: Order samples to feel the fabrics and see how your design looks before committing.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the perfect fabric to bring your custom t-shirt vision to life.

How to Get the Best Price for Designing Your Own Custom T-Shirts (Bulk Quantity Breaks, Artwork Tips)

Understand Bulk Quantity Breaks to Maximize Savings

When ordering custom t-shirts in bulk, most printers offer tiered pricing based on quantity. This means the more shirts you order, the lower the per-unit cost. To get the best deal:

• Know the Break Points: Common quantity breaks include 25, 50, 100, 250, and 500 units. For example, ordering 99 shirts may cost significantly more per shirt than ordering 100. Always aim to hit the next pricing tier.
• Consolidate Orders: If you’re unsure about future needs, consider ordering slightly more to take advantage of lower rates. Extra shirts can be stored or used for promotions.
• Compare Multiple Vendors: Different suppliers have varying break points and pricing structures. Use online quote tools from providers like Printful, Custom Ink, or SanMar to compare costs.

Choose the Right T-Shirt Style and Quality Wisely

Not all shirts are created equal—and price varies significantly based on fabric, brand, and weight:

• Opt for Value-Focused Brands: Gildan, Hanes, and Bella+Canvas offer affordable yet quality options suitable for bulk orders.
• Stick to One Style: Mixing shirt types increases setup costs and complicates pricing. Standardizing your design across one model simplifies production and reduces costs.
• Use Mid-Weight Cotton: 5.0–6.1 oz cotton shirts balance comfort, durability, and cost—ideal for most custom projects.

Simplify Your Artwork to Reduce Printing Costs

The complexity of your design directly impacts the price:

• Limit the Number of Print Colors: Each additional color increases screen setup fees in screen printing. Stick to 1–3 colors for the best pricing.
• Use Vector Art: Supply artwork in vector format (AI, EPS, or SVG) to avoid extra fees for file conversion. High-resolution PNGs (300 DPI) work for simpler prints.
• Avoid Full-Print or All-Over Designs: These require more ink and time. Focus on chest prints, sleeve details, or back logos to keep costs down.

Choose the Most Cost-Effective Printing Method

Different printing techniques suit various design needs and budgets:

• Screen Printing: Best for large orders (50+ units) with simple, bold designs. Low per-unit cost after setup.
• DTG (Direct-to-Garment): Ideal for detailed or full-color designs on smaller runs. Higher per-shirt cost but no setup fees for multiple colors.
• Dye Sublimation: Great for all-over prints on polyester blends. More expensive, so evaluate if necessary.

Order in Off-Peak Seasons

Timing your order can save money:

• Avoid Holidays and Summer Rushes: Demand spikes before events (e.g., graduations, festivals) can raise prices.
• Plan Ahead: Order 4–6 weeks in advance to avoid rush fees and ensure better pricing availability.

Request Samples Before Bulk Ordering

Always order a sample first:

• Confirm color accuracy, print quality, and shirt fit.
• Avoid costly reprints due to design or sizing errors.
• Some vendors offer discounted or free samples with bulk commitments.

Final Tips for Best Pricing

• Negotiate with Suppliers: Especially for large orders (500+), ask for a custom quote or discount.
• Bundle Services: Some printers offer discounts when you use their design tools or buy shipping in bulk.
• Check for Promo Codes: Look for seasonal sales, first-time customer discounts, or referral credits.

By leveraging bulk quantity breaks, optimizing your artwork, and choosing the right materials and methods, you can design high-quality custom t-shirts at the lowest possible price.