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

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

When ordering custom t-shirts, the fabric you choose impacts comfort, durability, appearance, and print quality. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you select the best option for your needs.

100% Cotton

100% cotton t-shirts are made entirely from natural cotton fibers. They are a classic choice known for softness and breathability.

Pros:
– Soft and comfortable, especially after washing
– Highly breathable, ideal for warm weather
– Absorbs ink well, making it great for vibrant screen printing
– Natural and biodegradable material

Cons:
– Prone to shrinking, especially if not pre-shrunk
– Can wrinkle easily
– Less durable over time; may fade or wear faster with frequent washing
– Heavier feel compared to blended fabrics

Best For: Everyday wear, promotional giveaways, eco-conscious brands, and designs requiring bold, opaque prints.

50/50 Blend (Cotton/Polyester)

A 50/50 blend combines equal parts cotton and polyester, offering a balanced mix of natural and synthetic fibers.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– More durable and long-lasting
– Lightweight and breathable with added structure
– Cost-effective and widely available

Cons:
– Slightly less soft than 100% cotton initially
– Less breathable than pure cotton
– Can retain odors and static more than cotton

Best For: Active environments, employee uniforms, events, and budget-friendly bulk orders where durability matters.

Tri-blends (Cotton/Polyester/Rayon)

Tri-blends typically consist of cotton, polyester, and rayon (often in ratios like 50/25/25). This combination creates a soft, drapey fabric with a vintage feel.

Pros:
– Exceptionally soft with a silky, luxurious hand feel
– Excellent drape and lightweight comfort
– Resists shrinking and fading better than 100% cotton
– Offers a slightly worn-in, vintage aesthetic

Cons:
– More expensive than cotton or 50/50 blends
– Less breathable due to polyester and rayon content
– Can be more delicate and prone to snagging
– May require gentler washing to maintain quality

Best For: Fashion-forward apparel, retail merchandise, boutique brands, and designs aiming for a premium, vintage look.

How to Choose

• Prioritize comfort and eco-friendliness? Go with 100% cotton.
• Need durability and affordability? Choose a 50/50 blend.
• Want a soft, stylish, high-end feel? Opt for a tri-blend.

Consider your audience, intended use, budget, and design style when selecting the right fabric for your custom t-shirts.

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 get the best possible price while maintaining quality, it’s important to understand how bulk pricing works and how to prepare your artwork efficiently. Here’s a comprehensive guide to help you save money and get professional results.

Understand Bulk Quantity Breaks

Most custom apparel suppliers offer tiered pricing based on the number of shirts ordered. These are known as quantity breaks—larger orders qualify for lower per-unit costs.

Common Quantity Break Tiers

• 1–24 units: Highest per-unit cost
• 25–49 units: Slight discount
• 50–99 units: Noticeable savings
• 100+ units: Best pricing (often 20–40% cheaper than small orders)

Tip: If you’re close to a quantity break (e.g., ordering 45 shirts), consider ordering 50 to take advantage of the lower rate. The extra shirts can serve as backups or future inventory.

Strategies to Maximize Savings

• Consolidate orders: Combine needs across departments or events.
• Order in advance: Plan for future needs to reach higher tiers.
• Standardize designs: Use the same design across multiple shirt colors/sizes to qualify for bulk pricing.

Choose the Right T-Shirt Style and Brand

Not all blanks are created equal. Basic cotton tees (like Gildan 5000) are usually the most affordable, while premium options (e.g., Bella+Canvas 3001) cost more.

Cost-Saving Tips:

• Stick with 6–8 common sizes (S–XXL) to avoid overstocking rare sizes.
• Use one consistent style and brand across your order—mixing increases setup and printing costs.
• Consider youth or women’s cuts only if necessary; unisex styles are typically cheaper and more versatile.

Optimize Your Artwork for Lower Printing Costs

The complexity of your design directly impacts printing costs. Simpler artwork = lower price.

Artwork Tips for Cost Efficiency

• Limit the number of print colors: Each additional color increases screen setup fees. Stick to 1–3 colors.
• Use vector files: Provide logos/art in vector format (AI, EPS, or PDF) for crisp, scalable printing.
• Avoid gradients and photo-realistic prints with standard screen printing—they require simulated process or DTG (direct-to-garment), which is more expensive.
• Design for one print location: Chest, back, or sleeve—each additional location adds cost.

Recommended File Specifications

• Resolution: 300 DPI for raster images
• Color Mode: CMYK or spot colors (not RGB)
• Bleed and margins: Keep critical elements 0.5” from edges

Compare Multiple Vendors

Pricing varies significantly between suppliers. Get quotes from at least 3–5 reputable printers.

What to Compare:

• Unit price at your target quantity
• Setup fees (often waived for large orders)
• Artwork assistance (free design tweaks?)
• Shipping costs and turnaround time
• Print method: Screen printing (cheaper for bulk), DTG (better for small runs or complex designs)

Pro Tip: Look for local screen printers—they may offer faster turnaround and lower shipping fees.

Time Your Order Strategically

• Avoid peak seasons: Summer and back-to-school periods often see higher demand and prices.
• Order early: Rush fees can add 15–25% to your total.
• Ask about promotions: Many vendors offer seasonal discounts or first-time customer deals.

Final Checklist Before Ordering

✅ Confirm quantity break thresholds with your vendor
✅ Finalize design and get approval from stakeholders
✅ Submit print-ready artwork in correct format
✅ Confirm fabric, fit, and color options
✅ Request a physical or digital proof before production

By leveraging bulk pricing, simplifying your design, and choosing the right vendor, you can significantly reduce the cost per shirt—getting high-quality custom apparel without overspending.