Comparison of Screen Printing, DTG, and Heat Transfer for Fast Custom T-Shirt Printing

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

When ordering custom t-shirts for your team, event, or brand, fabric choice is crucial—not just for comfort and style, but also for print quality and production speed. With fast turnarounds in mind, understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you make the best choice. Here’s what you need to know:

100% Cotton: Classic Comfort with Natural Appeal

100% cotton t-shirts are a timeless favorite thanks to their soft feel, breathability, and natural fibers. They’re ideal for warm weather and casual wear.

Pros for Fast Printing:
– Excellent ink absorption, especially with water-based and discharge inks, resulting in vibrant, soft prints.
– Widely available in blank stock, which speeds up sourcing and reduces lead time.
– Highly compatible with most printing methods, including screen printing and direct-to-garment (DTG).

Cons to Consider:
– Prone to shrinking (especially if not pre-shrunk), which may affect sizing consistency.
– Less durable over time—can fade or wear faster with frequent washing.
– May wrinkle easily and lack stretch, limiting comfort in fitted styles.

Best For: Eco-conscious brands, vintage-style designs, promotional tees, and screen printing with soft-hand inks.

50/50 Blend: The Best of Both Worlds

A 50/50 blend combines cotton and polyester, offering a balanced mix of comfort, durability, and performance.

Pros for Fast Printing:
– Resists shrinking and wrinkling better than 100% cotton, ensuring consistent sizing and a polished look.
– Holds up well to repeated washes, making it ideal for workwear or active use.
– Affordable and readily available, supporting quick turnaround times.
– Good compatibility with screen printing and DTG, especially with plastisol inks.

Cons to Consider:
– Polyester content can cause ink to sit on the surface rather than absorb, potentially leading to a stiffer print feel.
– Less breathable than 100% cotton, which may affect comfort in hot climates.
– Slight risk of pilling over time.

Best For: Budget-friendly bulk orders, corporate giveaways, event shirts, and applications where durability matters.

Tri-Blends: Softness and Style with a Modern Edge

Tri-blend fabrics typically mix cotton, polyester, and rayon (e.g., 50% polyester, 25% cotton, 25% rayon), creating a lightweight, ultra-soft fabric with a vintage drape.

Pros for Fast Printing:
– Exceptionally soft and comfortable with a luxurious feel—ideal for fashion-forward designs.
– Drapes beautifully, giving a more tailored, modern look.
– Resists shrinking and fading better than 100% cotton.
– Highly popular for premium custom apparel, adding perceived value.

Cons to Consider:
– More expensive than cotton or 50/50 blends, which can affect pricing and availability.
– Rayon content can make the fabric more delicate—requires careful handling during printing and washing.
– Limited availability in some blank shirt styles or colors, potentially extending lead times.
– May require special printing techniques or inks for optimal results.

Best For: Boutique brands, fashion lines, premium merch, and DTG printing with detailed, high-resolution designs.

Final Tips for Fast Turnarounds

• Choose High-Stock Fabrics: Opt for popular weights and colors (like 6.1 oz. 100% cotton or 50/50 crewnecks in black or white) to ensure quick sourcing.
• Match Fabric to Print Method: DTG works well on cotton-rich fabrics; plastisol handles blends effectively.
• Pre-Shrunk is Key: Always select pre-shrunk garments to avoid fit issues and delays.
• Consult Your Printer: Share your timeline and design—experienced printers can recommend the best fabric for speed and quality.

By aligning your fabric choice with your printing needs and delivery timeline, you’ll get custom t-shirts that look great, feel comfortable, and arrive fast.

How to Get the Best Price for Fast Custom T-Shirt Printing (Bulk Quantity Breaks & Artwork Tips)

Getting high-quality custom t-shirts quickly and affordably is possible with the right strategy. Whether you’re ordering for an event, business, or promotional campaign, these tips will help you save money—especially when ordering in bulk—while ensuring fast turnaround and professional results.

Bulk Quantity Breaks: Save Big on Large Orders

One of the most effective ways to reduce per-unit costs is by leveraging bulk pricing. Most reputable printers offer tiered pricing, where the cost per shirt drops significantly as your order size increases.

• Order in Larger Quantities: Typically, price breaks occur at 50, 100, 250, and 500+ units. For example, ordering 100 shirts may cost $8 each, while 250 shirts could drop to $5.50 each—saving you over 30%.
• Combine Orders: If you’re part of a team or organization, pool orders together to reach higher tiers and share the savings.
• Plan Ahead: Forecast your needs and place larger orders to lock in lower prices, even if you don’t need all shirts immediately. Most quality blanks have a long shelf life.

Choose the Right Printing Method for Speed and Cost

The printing technique impacts both cost and turnaround time. For bulk orders, some methods are more efficient than others.

• Screen Printing: Ideal for large quantities (50+ units) with simple designs. It has a setup fee but becomes very cost-effective at scale. Fast turnaround once screens are made.
• DTG (Direct-to-Garment): Best for detailed or full-color designs, but more expensive per unit and slower for large runs. Use DTG only if your design requires it.
• Plastisol Transfers: A faster alternative for small to mid-sized bulk orders with quick deadlines, though slightly less durable than screen printing.

Optimize Your Artwork to Reduce Costs and Speed Up Production

A well-prepared design not only looks better but also minimizes setup time and potential errors—saving you money and delays.

• Use Vector Files: Supply logos or artwork in vector format (AI, EPS, or SVG) for crisp, scalable printing. Raster images (JPG, PNG) can pixelate and may require costly redrawing.
• Simplify Your Design: Fewer colors = lower printing costs (especially for screen printing, where each color requires a separate screen). Aim for 1–3 colors when possible.
• Follow Print Area Guidelines: Avoid printing too close to seams or edges. Most printers have standard print zones—staying within them prevents extra setup fees.
• Submit Print-Ready Files: Include proper bleed, color mode (CMYK), and resolution (300 DPI). Double-check sizing and positioning to avoid proofing delays.

Compare Multiple Vendors & Use Promo Codes

Don’t settle for the first quote. Many online printers offer competitive rates and frequent discounts.

• Request Quotes from 3–5 Suppliers: Compare not just price, but also turnaround time, shipping costs, and customer reviews.
• Look for Seasonal Deals: Many printers offer discounts during back-to-school, holidays, or end-of-quarter sales.
• Use Promo Codes: Search for “custom t-shirt printing coupon” or sign up for vendor newsletters to get first-order discounts.

Choose Standard Apparel Options

Premium or specialty garments increase costs. To keep prices low:

• Stick to Basic Colors: White and black are cheapest; fashion or neon colors may cost more.
• Select Popular Brands: Gildan, Hanes, and Bella+Canvas offer quality at lower price points due to volume discounts.
• Avoid Upgrades: Pocket shirts, performance fabrics, or women’s fitted cuts cost more. Use them only if necessary.

Final Tips for Fast, Affordable Results

• Approve Proofs Quickly: Respond to digital proofs within 24 hours to avoid production delays.
• Pay for Rush Processing (If Needed): Some vendors offer 2–3 day turnaround for a small fee—worth it if you’re on a tight deadline.
• Bundle Shipping: Choose a single bulk shipment instead of multiple deliveries to reduce freight costs.

By combining bulk ordering, smart design practices, and strategic vendor selection, you can get fast, professional custom t-shirts at the best possible price. Plan early, prepare your artwork correctly, and always compare options to maximize value.