Comparison of Custom T-Shirt Printing Methods

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

When ordering custom t-shirts quickly—whether for events, promotions, or merchandise—selecting the right fabric is crucial. It affects comfort, durability, print quality, and overall appearance. Here’s a breakdown of the three most popular fabric types to help you make the best choice for your fast-turnaround project.

100% Cotton: Classic Comfort and Softness

100% cotton t-shirts are the traditional favorite for good reason. Made entirely from natural cotton fibers, they offer a soft, breathable feel ideal for everyday wear.

Pros:
– Extremely soft and comfortable, especially after washing
– Breathable and great for warm weather
– Excellent for screen printing—ink adheres well for vibrant colors
– Natural, eco-friendly material (especially if organic)

Cons:
– Prone to shrinking (typically 5–7%) if not pre-shrunk
– Less durable over time; may pill or wear thin with frequent washing
– Can wrinkle easily and lose shape faster than blended fabrics

Best For: Classic unisex tees, eco-conscious brands, events in warm climates, or when a vintage, natural cotton feel is preferred.

50/50 Blend: The Balanced Performer

A 50/50 blend combines 50% cotton and 50% polyester, offering a middle ground between natural softness and synthetic durability.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– Holds its shape longer and is more durable with repeated use
– Slightly lighter weight than 100% cotton
– Good print surface for both screen printing and direct-to-garment (DTG)

Cons:
– Less breathable than 100% cotton
– Can feel slightly less soft to the touch (though modern versions have improved)
– Polyester content may retain odors more than cotton

Best For: Budget-friendly promotional shirts, team uniforms, or situations where durability and consistent sizing matter more than ultra-softness. Ideal when you need shirts fast and want reliable performance.

Tri-Blends: Premium Softness with a Modern Feel

Tri-blend fabrics typically mix 50% polyester, 25% combed cotton, and 25% rayon (sometimes modal or another fiber). This creates a buttery-soft, lightweight fabric with a slight drape.

Pros:
– Exceptionally soft with a lived-in, vintage feel right from the start
– Minimal shrinkage and excellent shape retention
– Smooth surface ideal for detailed DTG prints
– Drapes beautifully, giving a more fitted, modern look

Cons:
– More expensive than cotton or 50/50 options
– Less breathable due to high polyester content
– May not hold up as well to heavy-duty use or frequent washing
– Not ideal for traditional screen printing with plastisol inks

Best For: Fashion-forward designs, boutique brands, women’s or fitted styles, and soft-hand feel apparel. Great for trendy, limited-run items when speed and style are both priorities.

Final Tips for Fast Custom T-Shirt Orders

• Turnaround Time: All three fabric types are widely available and suitable for fast production. Tri-blends may have slightly longer lead times depending on stock.
• Printing Method: Match your fabric to your print method—100% cotton and 50/50 blends work best with screen printing; tri-blends shine with DTG.
• Intended Use: Consider who will wear the shirts and where. Cotton for comfort, 50/50 for durability, tri-blend for style.
• Care Instructions: Always provide care guidelines, especially for cotton (cold wash, low dry) to minimize shrinkage.

Choose the fabric that aligns with your brand, audience, and timeline—and you’ll have custom t-shirts that look great and arrive fast.

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

Getting custom t-shirts quickly and affordably is possible with smart planning and strategic choices. Whether you’re ordering for a team, event, or business, these tips will help you save money—especially when ordering in bulk—while ensuring high-quality results and fast turnaround.

Leverage Bulk Quantity Breaks

Most custom apparel printers offer significant discounts when you order larger quantities. Understanding how bulk pricing works can save you hundreds.

• Know the Thresholds: Quantity breaks typically occur at 25, 50, 100, 250, and 500 units. For example, the price per shirt might drop sharply at 50 or 100 pieces. Always ask for a pricing chart to compare costs.
• Order Slightly Above the Breakpoint: If the next discount starts at 100 shirts, consider ordering 105 instead of 99. The marginal cost per shirt will be much lower.
• Consolidate Designs: If you need multiple designs, try to minimize variations. Each unique design (especially with different prints) can increase setup fees. Stick to one or two designs across sizes and colors to maximize savings.
• Choose One Color for All Sizes: Mixing colors or styles (e.g., men’s, women’s, youth) can affect pricing. Ordering in a single color and style simplifies fulfillment and may unlock better pricing.

Optimize Your Artwork for Lower Costs

The artwork you provide directly impacts printing costs and turnaround time. Follow these tips to avoid extra fees and delays.

• Use Vector Art (AI, EPS, SVG): Vector files scale to any size without losing quality and are preferred by printers. They reduce setup time and prevent rework fees.
• Simplify Your Design: Fewer colors = lower printing costs. Screen printing charges extra per ink color. A 1- or 2-color design is much cheaper than a 5-color one.
• Avoid Gradients and Photo Realism: These require simulated process printing, which is more expensive. Opt for flat colors and bold lines when possible.
• Submit Print-Ready Files: Ensure your artwork is high resolution (300 DPI), correctly sized, and includes proper bleed and safe zones. This avoids delays and extra design service fees.
• Use the Printer’s Templates: Most companies offer free design templates. Using them ensures your artwork fits the print area and reduces errors.

Speed Up Production with Smart Choices

Need your shirts fast? These strategies help maintain speed without blowing your budget.

• Choose In-Stock Shirt Styles: Select from blank t-shirts the supplier already has in inventory. This reduces sourcing time and potential delays.
• Pick Simpler Printing Methods: Screen printing is faster and cheaper for large orders with few colors. DTG (direct-to-garment) is great for complex designs but slower and more expensive in bulk.
• Order Early and Plan Ahead: Even with rush services, planning ahead gives you more pricing options. Last-minute orders often incur 25–50% rush fees.
• Use Local or Regional Printers: Proximity can reduce shipping time and cost, especially for urgent orders.

Final Tips for the Best Value

• Get Multiple Quotes: Compare at least 3–5 suppliers. Online printers like Printful, Custom Ink, and RushOrderTees often have competitive bulk pricing.
• Ask About Promo Codes and Seasonal Deals: Many vendors offer first-time discounts or holiday sales.
• Consider Long-Term Needs: If you’ll re-order, ask about loyalty discounts or reserved pricing for future runs.

By leveraging bulk discounts, optimizing your artwork, and choosing the right production methods, you can get high-quality custom t-shirts fast—and at the best possible price.