Comparison of Custom T-Shirt Printing Methods: Screen Printing, DTG, and Heat Transfer

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

When designing custom t-shirts for your local business, team, or event, the fabric choice is just as important as the design itself. The right material affects comfort, durability, appearance, and how your logo or artwork looks after printing. Here’s a breakdown of the three most popular fabric types to help you make the best decision.

100% Cotton: Classic Comfort and Softness

Pros:
– Soft and Breathable: Offers a natural, soft hand feel and excellent breathability, making it ideal for warm weather or active wear.
– Great Print Surface: Provides a smooth, consistent base for screen printing and DTG (direct-to-garment) printing, resulting in vibrant, crisp designs.
– Eco-Friendly Option: Biodegradable and widely recyclable, appealing to environmentally conscious customers.
– Natural Drape: Hangs well and feels familiar and comfortable to most people.

Cons:
– Prone to Shrinking: Can shrink significantly (up to 5–7%) if not pre-shrunk or washed improperly.
– Less Durable Over Time: Tends to wear out faster, especially with frequent washing; may develop pilling or thinning.
– Wrinkles Easily: Requires ironing for a crisp look and may wrinkle during wear or storage.

Best For: Casual wear, events, retail merchandise, and customers who prioritize comfort and a classic t-shirt feel.

50/50 Blend: The Balanced Performer

Pros:
– Durability: The polyester content increases strength and resistance to shrinking, fading, and pilling.
– Reduced Shrinkage: Typically shrinks less than 100% cotton (around 3%), making sizing more predictable.
– Affordable: Usually priced between 100% cotton and tri-blends, offering good value.
– Wrinkle-Resistant: Holds its shape better and resists creasing.

Cons:
– Less Breathable: Polyester content reduces airflow, which may feel warmer in hot climates.
– Slightly Stiffer Feel: Can feel coarser or less soft than cotton or tri-blends, especially in lower-quality versions.
– Print Absorption: May not absorb ink as well as cotton, potentially affecting print vibrancy with some printing methods.

Best For: Workwear, promotional giveaways, schools, or situations where durability and consistent sizing are priorities.

Tri-Blends: Premium Softness and Style

Pros:
– Ultra-Soft Hand Feel: A blend of cotton, polyester, and rayon (often 50/25/25) creates a luxuriously soft, slightly drapey fabric.
– Excellent Drape: Flatters the body and moves gracefully, similar to a lightweight sweater.
– Reduced Shrinkage: Pre-shrunk and stable, with minimal shrinkage after washing.
– Vintage Aesthetic: Often has a heathered or slightly worn-in look that enhances modern designs.

Cons:
– Higher Cost: Typically the most expensive option due to materials and manufacturing.
– Less Durable for Heavy Use: While soft, it may not withstand heavy-duty wear or frequent industrial laundering as well as cotton or 50/50 blends.
– Special Care Needed: May require gentler washing (cold water, lay flat to dry) to maintain appearance and softness.

Best For: Fashion-forward brands, boutique merchandise, gift items, or when you want a high-end, soft, and stylish look.

Choosing the Right Fabric for Your Needs

• Prioritize comfort and classic feel? → Go with 100% Cotton
• Need durability and budget-friendly performance? → Choose 50/50 Blend
• Want a premium, soft, and stylish shirt? → Opt for Tri-Blend

Consider your audience, use case, budget, and desired print quality when making your choice. Many local print shops offer fabric samples—request them to feel the differences firsthand before placing your order.

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

Understand Bulk Quantity Breaks

One of the most effective ways to reduce the cost per unit for custom t-shirts is by taking advantage of bulk quantity breaks. Most local screen printing and embroidery shops offer tiered pricing based on how many shirts you order. Here’s how to maximize savings:

• Order in larger quantities: Prices typically drop significantly at volume thresholds like 24, 48, 72, 100, or 250 units. For example, ordering 100 shirts may cost $8 each, but 250 could bring the price down to $5 per shirt.
• Ask for a price break chart: Request a detailed breakdown from your local printer showing cost per unit at different quantities. This helps you decide the most cost-effective order size.
• Consolidate orders: If you’re part of a team, club, or organization, coordinate with others to combine orders and reach higher volume tiers.
• Plan ahead: Larger orders mean more upfront cost, but save money long-term. Store extra shirts properly to avoid waste.

Choose the Right T-Shirt Style and Brand

Not all blank t-shirts are created equal — and pricing varies widely based on brand, fabric, and cut.

• Opt for value-priced blanks: Brands like Gildan, Hanes, and Alta Grande offer durable, budget-friendly options ideal for bulk printing.
• Stick to standard colors: White, black, and navy are usually the cheapest. Specialty or fashion colors may increase costs.
• Avoid premium features: Fleece, organic cotton, or designer brands (e.g., Bella+Canvas soft styles) increase base costs. Use them only if essential.

Simplify Your Design for Lower Printing Costs

The complexity of your artwork directly impacts printing price, especially with screen printing.

• Limit the number of print colors: Each additional color requires a separate screen and setup fee. A 1-color design is significantly cheaper than 4-color.
• Use one print location: Printing on the front only is less expensive than front + back or sleeve designs.
• Choose screen printing for large runs: It’s more cost-effective for 24+ shirts, especially with simple designs.
• Consider DTG (Direct-to-Garment) for small batches: For under 24 shirts or highly detailed designs, DTG may be more affordable despite higher per-unit cost.

Prepare Your Artwork Properly

Well-prepared artwork reduces setup time and avoids costly revisions.

• Use vector files (AI, EPS, SVG): These scale perfectly and are preferred by printers for clean prints.
• Submit high-resolution PNG or PDF (300 DPI): If you don’t have vector art, high-res raster files prevent pixelation.
• Outline all fonts: Convert text to outlines to prevent font issues.
• Keep design within print limits: Confirm the print area size with your printer to avoid cropping.
• Provide color codes (Pantone, RGB, or CMYK): Ensures accurate color matching, especially important for brand consistency.

Get Multiple Quotes and Build Relationships

• Shop around locally: Contact at least 3–5 local printers for quotes. Compare not just price, but turnaround time, quality, and customer service.
• Ask about setup and art fees: Some shops waive or reduce these for repeat customers or large orders.
• Build a relationship: Regular orders with the same printer can lead to discounts, priority service, and better pricing over time.

Time Your Order Wisely

• Avoid peak seasons: Summer (for events, festivals) and back-to-school periods can mean higher demand and prices.
• Allow ample production time: Rush orders often come with 25–50% surcharges. Plan 2–3 weeks ahead when possible.

By leveraging bulk pricing, simplifying designs, preparing professional artwork, and working with reliable local vendors, you can get high-quality custom t-shirts at the best possible price.