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

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

When ordering custom t-shirts on the same day, selecting the right fabric is crucial for both comfort and print quality. Here’s a breakdown of the three most popular options to help you make an informed decision quickly.

100% Cotton: Classic Comfort and Softness

100% cotton t-shirts are a timeless favorite known for their soft feel and breathability. Made entirely from natural cotton fibers, these shirts offer excellent moisture absorption, making them ideal for warmer weather or active wear. They’re typically heavier and more durable than blended fabrics, which contributes to a premium hand feel. However, they are more prone to shrinking (especially if not pre-shrunk) and may wrinkle more easily. For screen printing, cotton provides a smooth, absorbent surface that holds vibrant ink well—perfect for bold, detailed designs. Best for: Casual wear, promotional events, and customers who prioritize natural fibers and a classic t-shirt feel.

50/50 Blend: The Best of Both Worlds

A 50/50 blend combines equal parts cotton and polyester, offering a balanced mix of comfort and performance. The cotton maintains softness and breathability, while the polyester adds durability, wrinkle resistance, and reduced shrinkage. These shirts tend to be lighter in weight and dry faster than 100% cotton, making them great for active environments or humid climates. They also resist pilling better over time. When it comes to printing, 50/50 blends accept ink well and maintain design integrity through multiple washes. Their affordability and versatility make them a go-to choice for businesses needing reliable, cost-effective custom tees on short notice. Best for: Employee uniforms, event giveaways, and budget-conscious orders with a need for durability.

Tri-blends: Lightweight Luxury and Modern Style

Tri-blend fabrics typically consist of cotton, polyester, and rayon (often in a 50/25/25 or similar ratio), creating a uniquely soft, lightweight, and slightly heathered look. The addition of rayon gives tri-blends a silky drape and vintage aesthetic, making them popular for fashion-forward apparel. They’re highly breathable and comfortable against the skin, ideal for layering or warm-weather wear. However, they are generally more delicate than cotton or 50/50 blends and may require gentler washing. For same-day printing, tri-blends work well with water-based inks that preserve their soft hand feel. Note: Avoid heavy plastisol prints, as they can crack on the stretchier fabric. Best for: Boutique brands, trendy merch, and customers seeking a premium, soft, and stylish look.

Final Tips for Same-Day Orders

• Consider the use case: Choose cotton for durability, 50/50 for balance, and tri-blend for style.
• Check print method compatibility: Some fabrics work better with specific inks. Confirm with your printer.
• Think about care instructions: Inform recipients how to wash the shirts to maintain quality, especially with tri-blends.
• Order samples if possible: Even with tight timelines, a quick fabric swatch can prevent surprises.

By understanding these fabric differences, you can confidently select the perfect material for your same-day custom t-shirts—ensuring both customer satisfaction and professional results.

How to Get the Best Price for Same-Day Custom T-Shirts (Including Bulk Discounts & Artwork Tips)

Need custom t-shirts fast? Same-day turnaround is possible, but it often comes at a premium. However, with smart strategies—especially around bulk ordering and artwork preparation—you can significantly reduce costs without sacrificing quality. Here’s how to get the best price on same-day custom t-shirts in bulk.

Leverage Bulk Quantity Breaks

One of the most effective ways to lower your per-unit cost is by ordering in bulk. Most reputable screen printers and print-on-demand services offer tiered pricing based on volume.

• Order More, Pay Less Per Shirt: Prices typically drop at key thresholds like 24, 48, 72, or 100+ units. For example, ordering 100 shirts might reduce the unit price by 30–50% compared to ordering just 24.
• Plan Ahead When Possible: Even if you need shirts fast, place your order early in the day. Many printers offer same-day service if orders are submitted by 10–11 AM local time.
• Combine Orders with Others: If your event or team doesn’t need a large quantity, team up with another group to hit a higher quantity tier and split the savings.
• Choose a Standard Product: Stick with popular, in-stock shirt brands and colors (like Gildan, Bella+Canvas, or Hanes). This reduces setup time and avoids markup for specialty items.

Optimize Your Artwork to Save Money

Your design choices directly impact printing costs—especially with time-sensitive orders.

• Simplify Your Design: Fewer colors = lower screen printing costs. Designs with 1–3 colors are significantly cheaper than full-color or photorealistic prints.
• Use Vector Art (EPS, AI, SVG): Submit high-resolution vector files for crisp, scalable prints. Avoid low-res JPEGs or PNGs, which can result in poor quality and extra charges for redrawing.
• Stick to One Print Location: Printing on just the front or back is cheaper than multi-location printing (e.g., front + sleeve). If branding is essential, prioritize one main location.
• Avoid Large Solid Prints: Big blocks of ink use more material and may require additional drying time, increasing costs. Opt for designs with less ink coverage when possible.
• Provide Print-Ready Files: Ensure your artwork is properly formatted (correct dimensions, 300 DPI, outlined fonts) to avoid delays and extra setup fees.

Additional Tips for Same-Day Savings

• Compare Local Print Shops: Many local screen printers offer rush services and same-day turnaround. Call ahead to confirm availability and pricing.
• Ask About Rush Fees: Some vendors waive or reduce rush fees for bulk orders. Always inquire.
• Choose Screen Printing Over DTG for Bulk: For large quantities (24+), screen printing is usually cheaper and faster than direct-to-garment (DTG) printing, especially with simple designs.
• Be Flexible with Shirt Style/Color: Common colors (black, navy, white) are usually in stock and cheaper. Exotic colors or styles may delay your order or increase cost.

By combining bulk ordering, smart design choices, and strategic vendor selection, you can get high-quality custom t-shirts fast—and at the best possible price.