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

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

When you’re in a rush to get custom t-shirts for an event, promotion, or team, it’s tempting to focus only on speed and price. But the fabric you choose dramatically impacts comfort, durability, appearance, and how your design looks—especially under tight deadlines. Here’s a breakdown of the three most popular fabric types to help you make the best choice fast.

100% Cotton: Classic Comfort and Breathability

Pros:
– Soft and Breathable: Naturally soft against the skin and highly breathable, ideal for warm weather or active wear.
– Eco-Friendly: Biodegradable and made from a renewable resource.
– Great for Printing: Holds vibrant screen prints and DTG (direct-to-garment) designs well, especially on lighter colors.
– Familiar Feel: Offers the traditional t-shirt experience most people expect.

Cons:
– Prone to Shrinkage: Can shrink up to 5–10% if not pre-shrunk—critical to consider when ordering for a rush deadline.
– Less Durable Over Time: May wear out faster with repeated washing and is more susceptible to pilling.
– Wrinkles Easily: Requires ironing for a crisp look.

Best For Rush Orders When: You need a natural, comfortable feel for events in warm climates, or when printing bold, full-color designs on light-colored shirts.

50/50 Cotton-Polyester Blend: Balanced Performance

Pros:
– Reduced Shrinkage: Polyester helps stabilize the fabric, minimizing shrinkage—perfect for rush orders where sizing must be precise.
– Durable and Wrinkle-Resistant: Withstands frequent washing and stays looking neat with minimal care.
– Affordable: Typically priced between 100% cotton and tri-blends, offering good value.
– Good Print Surface: Works well with most printing methods, including screen printing and heat transfers.

Cons:
– Less Breathable: Can feel warmer and less comfortable in hot weather compared to cotton.
– Slight Sheen: The polyester content may give a subtle synthetic look, especially on darker colors.
– Not as Soft Initially: May feel slightly stiffer than cotton or tri-blends until broken in.

Best For Rush Orders When: You need a durable, low-maintenance shirt for team uniforms, promotional giveaways, or events requiring multiple washes—without breaking the budget.

Tri-blend (Cotton/Polyester/Rayon): Premium Softness and Drape

Pros:
– Ultra-Soft Feel: Often described as “buttery” or “vintage-soft,” thanks to the rayon content.
– Excellent Drape: Flattering, slightly fitted look that moves with the body.
– Minimal Shrinkage: Blends are typically pre-shrunk and very stable.
– Vintage Aesthetic: Fades beautifully over time, giving a worn-in, retro look that many love.

Cons:
– Higher Cost: Usually the most expensive option, which can impact rush order budgets.
– Delicate Fabric: Less durable than cotton or 50/50 blends; more prone to snagging or pilling with heavy use.
– Limited Color Range: Often available in heathered or muted tones—not ideal if you need bright, solid colors.
– Printing Considerations: May require special inks or settings for optimal print results.

Best For Rush Orders When: You’re creating premium event shirts, boutique merch, or fashion-forward designs where softness and style are top priorities.

Final Tips for Rush Custom T-Shirt Orders

• Confirm Fabric Availability: Popular tri-blend colors may have longer lead times—verify stock before finalizing.
• Pre-Shrunk is Key: For rush orders, always opt for pre-shrunk fabrics to avoid sizing issues.
• Match Fabric to Use: High-activity events? Go cotton or 50/50. Fashion showcase? Try tri-blend.
• Consult Your Printer: Discuss your fabric choice with your custom apparel provider—they can advise on print quality and turnaround times.

Choosing the right fabric ensures your rush custom t-shirts look great, feel comfortable, and arrive on time—without compromising quality.

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

Ordering custom t-shirts quickly doesn’t have to break the bank. By leveraging bulk pricing and optimizing your artwork, you can secure high-quality rush orders at the best possible price. Here’s how:

Leverage Bulk Quantity Breaks for Lower Per-Unit Costs

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on quantity. The more you order, the lower the cost per shirt. To maximize savings:

• Order at the Threshold of Each Break: Prices typically drop at common thresholds like 24, 48, 72, 100, or 250 units. For example, 99 shirts may cost $8 each, but 100 could drop to $5.50. Always order just enough to hit the next break.
• Consolidate Needs Across Teams or Events: If possible, combine orders from different departments, events, or future needs to reach higher quantity tiers.
• Choose Standard Sizes and Colors: Opt for basic colors (like black, white, or navy) and standard unisex sizing. Premium or specialty colors and styles often cost more and may extend turnaround time.
• Minimize Color Variations: Stick to one or two shirt colors. Each additional color requires separate setup and can increase both price and production time.

Optimize Your Artwork to Reduce Production Costs

High-quality artwork not only looks better but also reduces printing complexity and cost—especially important for rush jobs.

• Use Vector Files (AI, EPS, SVG): Vector artwork scales infinitely without losing quality and is preferred by printers. Avoid blurry or pixelated images.
• Simplify Your Design: Fewer colors and less detail mean lower screen setup fees and faster printing. For screen printing, each color requires a separate screen and pass—aim for 1–3 colors max for cost efficiency.
• Submit Print-Ready Art: Provide files at 300 DPI resolution, in CMYK or PMS color mode (not RGB), and include proper bleed and safe zones. This reduces back-and-forth corrections that can delay a rush order.
• Avoid Photographic or Gradients (for Screen Printing): These require simulated process printing or DTG, which is more expensive. Use solid colors and flat design elements when possible.
• Confirm Artwork Acceptance Early: Submit your design as soon as you place the order. Many rush services require artwork approval before production begins, so delays here can push back your delivery.

Additional Tips for the Best Rush Pricing

• Compare Multiple Vendors: Use online instant quote tools from several reputable rush printing services (like RushOrderTees, CustomInk Rush, or local shops). Compare not just prices but also turnaround guarantees and setup fees.
• Avoid Last-Minute Rush Fees: The earlier you order, the better the pricing. “Same-day” or “24-hour” turnaround costs more than 3–5 day rush options. Plan ahead if possible.
• Bundle Printing Methods: For complex designs with many colors, consider combining screen printing (for large solid areas) with DTG (for detailed elements). Some vendors offer hybrid solutions at competitive rates.
• Ask About Promo Codes or Bulk Discounts: Many companies offer first-time discounts, loyalty rewards, or seasonal promotions—especially for bulk rush orders.

By strategically using bulk quantity breaks and preparing professional, print-ready artwork, you can get high-quality rush custom t-shirts faster and at a significantly lower cost.