Comparison of Custom T-Shirt Printing Methods

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

When printing custom t-shirts, the fabric you choose significantly 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. Here’s a breakdown of each:

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, comfortable feel ideal for warm weather and everyday wear.
– Eco-Friendly: Biodegradable and often made from renewable resources.
– Excellent Print Surface: Absorbs ink well, resulting in vibrant, crisp designs—especially with screen printing.
– Classic Look and Feel: Preferred for its traditional, vintage appeal.

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk or washed improperly.
– Less Durable: Can wear out faster and develop holes or thin spots over time.
– Wrinkles Easily: Requires ironing for a smooth appearance.
– Absorbs Moisture: Holds sweat, which may feel damp during physical activity.

Best For: Casual wear, promotional events, screen-printed designs, and those who prefer a natural fabric.

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

Pros:
– Balanced Comfort: Combines the softness of cotton with the durability of polyester.
– Reduced Shrinkage: More stable than 100% cotton, maintaining shape after washing.
– Fade and Wrinkle Resistant: Withstands repeated washes and holds color better over time.
– Affordable: Typically priced between 100% cotton and tri-blends.

Cons:
– Less Breathable: Polyester content can trap heat, making it less ideal for hot climates.
– Slight Sheen: May have a subtle synthetic look compared to natural cotton.
– Pilling: Can develop small fabric balls (pills) with heavy use.

Best For: Workwear, giveaways, active environments, and budget-conscious projects needing durability.

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

Pros:
– Ultra-Soft Feel: Often described as “buttery” or “vintage-soft” due to the rayon content.
– Excellent Drape: Flows smoothly over the body, creating a relaxed, flattering fit.
– Color Retention: Vibrant prints with a slightly heathered, retro aesthetic.
– Wrinkle Resistant: Maintains a smooth look with minimal care.

Cons:
– Less Durable: Softer fabric may wear faster with heavy use or frequent washing.
– Shrinking Risk: Can shrink if washed in hot water—cold washes recommended.
– Higher Cost: Generally more expensive than cotton or 50/50 options.
– Not Ideal for Heavy Ink: Delicate fabric may not support thick plastisol prints as well.

Best For: Fashion-forward tees, boutique brands, lightweight prints, and soft-hand screen or water-based ink designs.

Final Tips for Choosing

• Consider the Use: Will the shirt be worn daily, for sports, or as a fashion statement?
• Think About Climate: Cotton breathes best in heat; blends offer more moisture-wicking.
• Evaluate Print Method: Screen printing works well on all, but tri-blends shine with soft, vintage-style prints.
• Budget Matters: 50/50 blends offer a sweet spot between cost and performance.

By matching your fabric choice to your audience, purpose, and design, you’ll create custom t-shirts that look great and feel even better.

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, team, or event—but maximizing savings requires strategy. Here’s how to secure the best price by leveraging quantity breaks and optimizing your artwork.

Understand Bulk Quantity Breaks

Most custom apparel suppliers offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost. To take full advantage:

• Know the Thresholds: Suppliers typically have quantity tiers (e.g., 25, 50, 100, 250+ units). Prices drop significantly at each breakpoint. For example, ordering 100 shirts might cost $8 each, while 250 could drop to $5 each.
• Consolidate Orders: If possible, combine needs across departments, events, or teams to reach higher tiers.
• Consider Future Needs: If you’ll need more later, ordering a larger batch now (even if you don’t use all shirts immediately) can save money long-term.
• Compare Suppliers: Not all vendors have the same breakpoints. Use quote tools from multiple printers to find the best deal for your volume.

Choose the Right Shirt Style and Brand

• Opt for Value-Focused Brands: Gildan, Hanes, and Bella+Canvas offer high-quality basics at lower price points than premium brands.
• Stick to One Style: Mixing shirt types (e.g., crewnecks, V-necks, long sleeves) increases setup and production complexity, potentially raising costs.
• Standard Colors Save Money: White, black, and navy are usually less expensive than specialty or fashion colors.

Simplify Your Design for Lower Printing Costs

The complexity of your artwork directly impacts the price. Here’s how to keep it simple and affordable:

• Limit Print Colors: Each additional ink color increases screen setup fees. Stick to 1–3 colors whenever possible.
• Choose Efficient Print Methods:
• Screen Printing: Most cost-effective for large orders with simple designs.
• DTG (Direct-to-Garment): Better for detailed or full-color designs but more expensive per unit on bulk orders.
• Minimize Print Locations: Printing on just the front is cheaper than front + back or sleeves.

Optimize Your Artwork for Production

A print-ready design prevents delays and extra charges:

• Use Vector Files (AI, EPS, SVG): These scale perfectly and are preferred by printers. Avoid low-res JPEGs or PNGs.
• Specify Pantone (PMS) Colors: Ensures color accuracy and reduces guesswork for the printer.
• Keep It Clean and Simple: Avoid tiny text or intricate details that may not print well. Focus on bold, legible graphics.
• Follow Print Area Guidelines: Confirm the maximum print size with your supplier to avoid resizing issues.

Get Multiple Quotes and Negotiate

• Request Quotes from 3–5 Suppliers: Online tools make this easy. Include all specs: quantity, shirt type, print colors, locations.
• Ask About Promotions: Many printers offer seasonal discounts, free setup, or waived fees for first-time bulk orders.
• Negotiate Setup Fees: For large orders, ask if screen or artwork setup fees can be reduced or waived.

Order Samples First

Before committing to a full bulk order, get a physical sample. This ensures the shirt quality, print accuracy, and sizing meet expectations—avoiding costly reprints.

By combining smart bulk ordering, simplified designs, and print-ready artwork, you can significantly reduce your per-shirt cost while still getting professional-quality custom t-shirts.