Comparison of Screen Printing, DTG, and Heat Transfer for High-Quality Custom T-Shirts

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Right Fabric for High-Quality Custom T-Shirts

When creating custom t-shirts, the fabric choice is one of the most critical decisions you’ll make. It affects comfort, durability, appearance, printability, and overall perceived quality. Three of the most popular fabric options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s a detailed comparison to help you choose the best option for your custom apparel project.

100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and breathable: Offers excellent comfort, especially in warmer weather.
– Natural fibers: Hypoallergenic and biodegradable, appealing to eco-conscious consumers.
– Great for printing: Holds vibrant ink well, especially with screen printing and direct-to-garment (DTG) methods.
– Absorbent: Feels comfortable against the skin and absorbs moisture effectively.

Cons:
– Prone to shrinking: Can shrink significantly after washing if not pre-shrunk.
– Less durable: More susceptible to wear, pilling, and stretching over time.
– Wrinkles easily: Requires ironing or steaming for a crisp look.
– May fade: Colors can fade faster with repeated washing compared to synthetic blends.

Best For: Everyday wear, casual brands, eco-friendly lines, and customers who prioritize natural materials and softness.

50/50 Cotton-Polyester Blend: The Balanced Workhorse

Pros:
– Durable and long-lasting: Resists shrinking, stretching, and pilling better than 100% cotton.
– Low maintenance: Wrinkle-resistant and dries quickly, making it ideal for active use.
– Affordable: Typically less expensive than high-end cotton or tri-blend fabrics.
– Good print surface: Works well with most printing techniques, including vinyl, screen printing, and heat transfer.

Cons:
– Less breathable: Polyester content can trap heat and moisture, making it less comfortable in hot climates.
– Slightly stiffer feel: May not feel as soft as 100% cotton or tri-blends initially.
– Less eco-friendly: Polyester is a synthetic fiber derived from petroleum and is less biodegradable.

Best For: Promotional apparel, workwear, school events, and high-volume orders where durability and cost-efficiency are key.

Tri-Blend (Usually Cotton, Polyester, Rayon): Premium Softness and Drape

Pros:
– Exceptionally soft: Often described as having a “buttery” or vintage feel right from the start.
– Excellent drape: Flattering fit with a slightly relaxed, lived-in look that moves with the body.
– Moisture-wicking and breathable: Better than 50/50 blends due to rayon and cotton content.
– Reduced shrinkage: More stable than 100% cotton, especially after pre-shrinking.
– Vintage aesthetic: Fades beautifully over time, appealing for fashion-forward or lifestyle brands.

Cons:
– Higher cost: More expensive due to the combination of materials and processing.
– Delicate care needed: May require gentle washing and air drying to maintain quality and shape.
– Print limitations: Some printing methods may require adjustments due to fabric stretch and composition.

Best For: Fashion brands, boutique apparel, gift items, and customers seeking a premium, soft, and stylish garment.

Final Tips for Choosing the Right Fabric

• Know your audience: Are they eco-conscious, budget-minded, or fashion-focused?
• Consider the use case: Will the shirt be worn daily, for sports, or as a keepsake?
• Evaluate print design: Intricate or colorful designs may work better on certain fabrics.
• Request samples: Always order fabric swatches or sample shirts to assess hand feel, weight, and print quality firsthand.
• Check garment specs: Look at fabric weight (measured in ounces per square yard), thread count, and pre-shrinking details.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently select the ideal fabric that aligns with your brand’s values, budget, and customer expectations for high-quality custom t-shirts.

How to Get the Best Price for High-Quality Custom T-Shirts (With Bulk Savings & Artwork Tips)

Ordering custom t-shirts in bulk doesn’t have to break the bank — especially when you know how to leverage quantity discounts and optimize your design process. Follow these expert tips to get top-quality shirts at the best possible price.

Understand Bulk Quantity Breaks and Pricing Tiers

Most reputable screen printers and online suppliers offer significant savings through volume discounts. Here’s how to maximize them:

• Order in Standard Increments: Suppliers often have pricing tiers at 12, 24, 48, 72, 144, 288, and 500+ units. Jumping to the next tier (e.g., from 48 to 72) can drastically reduce the per-unit cost.
• Consolidate Designs: Instead of ordering small batches of many designs, combine similar designs or use color variations to fill a larger order. For example, one design in five colors on 100 shirts is cheaper than five different designs at 20 shirts each.
• Plan Ahead for Future Needs: If you anticipate needing shirts later (e.g., for events or staff), combine orders to hit higher quantity breaks and save long-term.

Choose the Right T-Shirt Style and Material

High quality doesn’t mean overpriced — it means selecting fabrics that balance comfort, durability, and cost:

• Opt for 100% Combed Cotton or Cotton Blends: These provide a premium feel at a reasonable cost. Blends (e.g., 50/50 cotton-polyester) offer durability and wrinkle resistance, ideal for workwear or active use.
• Stick to Popular Brands: Brands like Gildan Heavy Cotton, Bella+Canvas 3001, or Next Level 6010 offer excellent quality and are widely available at competitive prices due to high volume production.
• Avoid Overly Niche Styles: Specialty cuts (v-necks, tank tops, performance fabrics) often cost more and may not qualify for the same bulk discounts.

Optimize Your Artwork for Lower Printing Costs

The design directly impacts your final price — especially with screen printing. Follow these artwork best practices:

• Limit the Number of Colors: Each color requires a separate screen and setup fee. Stick to 1–3 colors to reduce costs significantly. Use color blending techniques (like halftones) to simulate more colors without extra screens.
• Use Vector Art (AI, EPS, SVG): High-resolution vector files ensure crisp printing and prevent upcharges for file correction. Avoid low-res JPEGs or PNGs.
• Simplify Your Design: Complex artwork with gradients, fine details, or photorealistic elements increases printing time and cost. Simplified, bold designs print faster and look sharper.
• Position Prints Strategically: Chest prints are cheaper than full-front, back, or sleeve prints. Avoid multi-location printing unless absolutely necessary.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote:

• Compare 3–5 Reputable Suppliers: Look at both online platforms (like Custom Ink, Printful, or RushOrderTees) and local screen printers. Local shops may offer better deals for large runs and faster turnaround.
• Ask About Hidden Fees: Confirm whether setup fees, screen fees, shipping, and tax are included. Some suppliers offer “all-in” pricing for bulk orders.
• Negotiate for Repeat Business: If you plan future orders, mention it. Many suppliers offer loyalty discounts or reduced setup fees for returning customers.

Time Your Order Strategically

• Avoid Peak Seasons: Ordering during holidays or back-to-school periods can lead to higher prices and longer lead times. Plan orders during off-peak months (e.g., late winter or mid-summer).
• Take Advantage of Promotions: Many suppliers run seasonal sales (e.g., “50% off setup fees” or “Free shipping on orders over 100”). Sign up for newsletters to stay informed.

Request a Physical Sample

Before committing to a bulk order:

• Order a Sample First: Pay for one printed shirt to evaluate print quality, fabric feel, and color accuracy. It’s a small investment that prevents costly mistakes.
• Check Color Matching: Use Pantone (PMS) or CMYK references to ensure brand consistency. Ask for a color proof if exact match is critical.

By combining smart bulk ordering, efficient design practices, and strategic supplier selection, you can achieve professional-quality custom t-shirts at a fraction of the expected cost.