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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Best Fabric for Your Custom T-Shirt

When designing custom t-shirts, one of the most important decisions you’ll make is choosing the right fabric. The material affects comfort, durability, appearance, and how well your design prints. Here’s a breakdown of the three most popular options: 100% cotton, 50/50 blends, and tri-blends.

100% Cotton

Pros:
– Soft and Breathable: Naturally soft against the skin and highly breathable, making it ideal for warm weather and active wear.
– Eco-Friendly: Biodegradable and typically made from renewable resources.
– Great for Printing: Absorbs ink well, resulting in vibrant, crisp prints—especially with screen printing.
– Classic Feel: Offers the traditional, comfortable t-shirt experience many people love.

Cons:
– Prone to Shrinking: Can shrink if not pre-shrunk or washed in hot water.
– Less Durable: May wear out faster than blended fabrics and is more susceptible to pilling.
– Wrinkles Easily: Tends to wrinkle and lose shape over time, especially after repeated washing.

Best For: Casual wear, eco-conscious brands, screen-printed designs, and those who prefer a natural fabric feel.

50/50 Blend (50% Cotton, 50% Polyester)

Pros:
– Durable and Long-Lasting: Polyester adds strength, helping the shirt resist wear, pilling, and shrinking.
– Wrinkle-Resistant: Holds its shape better and resists wrinkles compared to 100% cotton.
– Affordable: Often less expensive than tri-blends and offers good value.
– Lightweight: A balanced feel that’s soft but more resilient than pure cotton.

Cons:
– Less Breathable: Polyester reduces breathability, which may make it less comfortable in hot climates.
– Less Soft: Can feel slightly rougher than 100% cotton or tri-blends, especially in lower-quality versions.
– Print Quality: May not absorb ink as well as cotton, potentially affecting print vibrancy.

Best For: Promotional shirts, workwear, youth sizes, and high-volume orders where durability and cost are key.

Tri-Blend (Typically 50% Polyester, 25% Cotton, 25% Rayon)

Pros:
– Ultra-Soft and Lightweight: Combines the best qualities of each fiber for a buttery-smooth, luxurious hand feel.
– Excellent Drape: Flows beautifully and conforms to the body, giving a more fitted, modern look.
– Fade-Resistant: Polyester helps maintain color over time, even after multiple washes.
– Minimal Shrinkage: Highly stable fabric with little to no shrinkage.

Cons:
– Higher Cost: More expensive than 100% cotton or 50/50 blends due to the rayon content.
– Less Durable for Heavy Use: While soft, it can be more delicate and may not hold up as well to heavy-duty wear.
– Special Care Needed: Often requires gentle washing to maintain its softness and appearance.

Best For: Fashion-forward apparel, premium custom tees, retail brands, and designs needing a soft, vintage look with modern comfort.

Final Tips for Choosing

• Consider Your Audience: Are they looking for comfort, durability, or style?
• Think About Use Case: Will the shirts be worn daily, for events, or as merchandise?
• Match Fabric to Print Method: Some fabrics work better with DTG (Direct-to-Garment) printing, while others suit screen printing.
• Test First: Order samples to feel the fabrics and test print quality before committing to large quantities.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can confidently choose the perfect fabric for your custom t-shirt project.

How to Get the Best Price for 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. However, to truly get the best price, you need to understand quantity breaks, optimize your artwork, and make smart sourcing decisions. Here’s how to save money without sacrificing quality.

Leverage Bulk Quantity Breaks

Most screen printers and online custom apparel suppliers offer tiered pricing based on quantity. The more you order, the lower the per-unit cost.

• Know Standard Quantity Tiers: Common breaks include 12, 24, 48, 72, 100, 250, 500, and 1,000+ units. Ordering just above a tier (e.g., 51 instead of 48) can significantly reduce cost per shirt.
• Avoid the Minimum Trap: Some companies advertise low prices starting at 12 units, but the real savings kick in at 50+ units. Always compare unit prices across tiers.
• Consider Future Needs: If you plan to reorder, it’s often cheaper to order more upfront. Store extras properly to avoid shrinkage or style discontinuation.
• Mix Sizes, Not Styles: You can usually mix sizes within the same design and color to hit quantity breaks. Avoid splitting orders across multiple designs or colors, as setup costs apply to each.

Optimize Your Artwork for Cost Savings

The design complexity directly impacts printing costs. Simplifying your artwork can reduce both setup and print expenses.

• Limit Print Colors: Each additional color requires a separate screen and increases setup time. Stick to 1–3 colors to keep prices low. Use color blending techniques (like halftones) if needed.
• Choose Simpler Printing Methods: Screen printing is most cost-effective for bulk orders with simple designs. For complex, full-color designs, consider DTG (Direct-to-Garment), but note it’s pricier per unit and better for smaller runs.
• Provide High-Resolution, Vector Files: Supply artwork in vector formats (AI, EPS, SVG) or high-res PNG (300 DPI). This prevents rework fees and ensures clean prints.
• Size and Placement Matter: Smaller prints (e.g., left chest) are cheaper than large back prints. Centered designs may also reduce alignment time.
• Avoid Photo-Realistic Designs for Screen Printing: These require specialized techniques and more screens, driving up cost. Simplify or use DTG instead.

Additional Tips to Maximize Savings

• Compare Multiple Suppliers: Get quotes from at least 3–5 reputable printers. Local shops may offer faster turnaround, while online vendors (e.g., Custom Ink, Printful, RushOrderTees) often have competitive bulk rates.
• Choose Standard Shirt Styles and Colors: Basic colors (white, black, navy) and popular brands (Gildan, Bella+Canvas) are cheaper than specialty fabrics or trendy cuts.
• Bundle Services: Some suppliers offer discounts if you use their design tools or order matching apparel (hats, hoodies).
• Plan Ahead: Rush orders come with fees. Allow 2–3 weeks for production and shipping to qualify for standard pricing.
• Ask About Blank Garment Discounts: Large orders may qualify for lower blank shirt costs—don’t assume the listed price is final.

By strategically using quantity breaks, simplifying your design, and shopping wisely, you can significantly reduce the cost per custom t-shirt—without compromising on quality or impact.