Comparison Table: Screen Printing, DTG, and Heat Transfer for Low-Price Custom T-Shirts

100% Cotton vs. 50/50 Blend vs. Tri-Blend: Choosing the Best Fabric for Low-Price Custom T-Shirts

When ordering custom t-shirts on a budget, selecting the right fabric is crucial. It impacts not only the cost but also comfort, durability, and print quality. Here’s a breakdown of the three most common fabric types—100% cotton, 50/50 blend, and tri-blend—to help you make a smart, cost-effective decision.

100% Cotton: Classic Comfort at a Low Cost

100% cotton t-shirts are a popular choice for custom printing due to their soft feel and breathable nature. They’re ideal for everyday wear and offer a natural, vintage look that many customers love.

Pros:
– Soft and comfortable, especially after a few washes
– Excellent absorbency, great for warm climates
– Holds screen printing and direct-to-garment (DTG) ink well
– Widely available in low-cost blank options

Cons:
– Can shrink if not pre-shrunk (look for “ring-spun” or “pre-shrunk” labels)
– Less durable over time; may wear out faster with heavy use
– Prone to wrinkling and fading after repeated washing

Best For: Budget-friendly giveaways, promotional events, or casual apparel where softness and print clarity are priorities.

50/50 Blend (50% Cotton, 50% Polyester): Balanced Performance

A 50/50 blend combines the comfort of cotton with the durability and wrinkle-resistance of polyester. This blend often offers better value for money in the long run due to its enhanced durability.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– More durable and longer-lasting
– Often priced similarly to or only slightly above 100% cotton blanks
– Good print surface for both screen printing and DTG

Cons:
– Slightly less soft than 100% cotton (though modern versions are improving)
– Less breathable—can feel warmer in hot weather
– May pill over time with frequent washing

Best For: Workwear, school events, or any setting where shirts will be washed often and need to hold up over time.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon): Premium Feel, Higher Cost

Tri-blend fabrics offer a super soft, lightweight, and slightly heathered look. They drape well and have a more fashionable, vintage aesthetic.

Pros:
– Extremely soft with a silky, luxurious hand feel
– Excellent drape and comfort
– Resists shrinking and fading better than 100% cotton
– Stylish, modern appearance popular in retail apparel

Cons:
– Usually more expensive than 100% cotton or 50/50 blends
– May require special care (e.g., washing inside out, avoiding high heat)
– Not ideal for high-opacity screen printing—better for DTG or water-based inks

Best For: Fashion-focused brands, boutique orders, or higher-end giveaways where presentation matters more than ultra-low cost.

Final Tips for Choosing Low-Cost Custom T-Shirt Fabrics

• Prioritize your use case: For high-volume, low-cost needs, 100% cotton or 50/50 blends are usually best.
• Order samples: Always test print and feel actual fabric samples before bulk ordering.
• Check fabric weight: Lighter weights (e.g., 4.0–4.5 oz) cost less but may feel thin; mid-weight (5.0–6.1 oz) offers better durability.
• Buy in bulk: Larger orders reduce per-unit cost across all fabric types.
• Work with a reliable supplier: Choose a printer or blank supplier that offers quality budget options without cutting corners.

By understanding the trade-offs between 100% cotton, 50/50 blends, and tri-blends, you can choose the most cost-effective fabric that still meets your quality and design goals.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. But to truly get the best price, you need to understand how pricing works and how to optimize your order. Here’s how to save money without sacrificing quality.

Leverage Bulk Quantity Breaks

Screen printing and other customization methods become significantly cheaper per unit when you order in larger quantities. Most suppliers offer tiered pricing based on volume.

• Know the Thresholds: Common quantity breaks include 25, 50, 100, 250, and 500 units. Prices often drop dramatically at each threshold.
• Order Just Above the Break Point: If the next pricing tier starts at 100 shirts, ordering 100 instead of 99 can save you $2–$5 per shirt.
• Combine Orders: If possible, team up with others (colleagues, clubs, or partners) to reach a higher quantity tier and split the cost.
• Plan Ahead: If you’ll need shirts again in 6–12 months, consider ordering more now to take advantage of lower per-unit pricing—even if you don’t need them all immediately.

Choose the Right T-Shirt Style and Brand

Not all blanks are created equal—and price varies widely.

• Go Basic: 100% cotton, budget-friendly brands (like Gildan, Hanes, or Bella+Canvas 3001) offer the lowest base prices.
• Avoid Premium Features: Steer clear of ring-spun cotton, organic materials, or designer cuts unless necessary—they cost more.
• Stick to Standard Colors: White and basic colors (black, navy, grey) are cheaper than specialty or pastel hues.

Simplify Your Design to Cut Printing Costs

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

• Limit Print Colors: Each additional color requires a separate screen and setup fee. Stick to 1–3 colors for the lowest cost.
• Use One-Spot Color Designs: A single-color print is the most economical option.
• Minimize Print Locations: Printing on just the front (instead of front + back or sleeves) reduces labor and setup time.
• Avoid Large or All-Over Prints: Full-front or full-back designs use more ink and time—opt for smaller, centered designs.

Optimize Artwork for Production

Clean, print-ready artwork prevents costly revisions and delays.

• Use Vector Files (AI, EPS, SVG): These scale infinitely and are preferred by printers. Avoid low-res JPEGs or PNGs.
• Convert Text to Outlines: Prevent font issues by outlining all text in your design file.
• Use High Resolution (300 DPI): If submitting raster images (like Photoshop files), ensure they’re high-res to avoid blurriness.
• Follow the Printer’s Template: Use their size and bleed guides to ensure proper placement and avoid redesign fees.
• Keep It Simple: Crisp, bold designs with solid colors reproduce better and cheaper than detailed gradients or halftones.

Get Multiple Quotes and Negotiate

Never settle for the first quote.

• Compare at Least 3–5 Suppliers: Local screen printers, online services (like Custom Ink, Printful, or RushOrderTees), and print brokers all have different pricing models.
• Ask About Setup Fees: Some waive or reduce screen setup fees for repeat or large orders.
• Inquire About Rush Fees: Standard turnaround is cheaper. Avoid rush processing unless absolutely necessary.
• Negotiate: For large orders (250+), ask if they can offer a better deal—especially if you plan to reorder.

Final Tips for Maximum Savings

• Order in One Color and Size: Reducing size runs and color variations streamlines production and cuts costs.
• Bundle with Other Items: Some suppliers offer discounts when ordering shirts with hats, bags, or other apparel.
• Check for Promotions: Look for seasonal sales, first-time customer discounts, or free shipping offers.

By combining smart bulk ordering, simplified designs, and strategic supplier choices, you can get high-quality custom t-shirts at the lowest possible price. Plan ahead, prepare your artwork properly, and always compare options to ensure the best deal.