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

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

When ordering custom t-shirts for your shop, the fabric choice significantly impacts comfort, durability, appearance, and price. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you match the right material to your customer’s needs and brand goals.

100% Cotton: Classic Comfort and Softness

100% cotton t-shirts are the traditional favorite, known for their natural feel and breathability.

• Pros:
• Exceptionally soft and comfortable against the skin
• Highly breathable, ideal for warm weather or active wear
• Absorbs ink well, resulting in vibrant, crisp prints

• Biodegradable and eco-friendly (especially organic cotton options)

• Cons:

• Prone to shrinking, especially if not pre-shrunk
• Can wrinkle easily and lose shape over time

• Less durable than blended fabrics; may pill or wear faster with frequent washing

• Best For:
  Customers who prioritize softness and natural fibers; ideal for basic tees, eco-conscious brands, or screen printing with bold designs.

50/50 Blend: The Balanced Performer

A 50% cotton / 50% polyester blend combines the best qualities of both fibers, offering a versatile middle ground.

• Pros:
• Resists shrinking and wrinkling better than 100% cotton
• Holds its shape longer with repeated wear and washing
• More durable and resistant to pilling

• Affordable and widely available

• Cons:

• Slightly less breathable than 100% cotton
• May feel less soft initially (though modern versions are improving)

• Polyester can retain odors if not treated properly

• Best For:
  Budget-friendly custom shirts for events, promotions, or workwear; great for high-volume orders where durability matters.

Tri-Blends: Premium Softness and Drape

Tri-blend fabrics typically combine cotton, polyester, and rayon (e.g., 50% polyester, 25% cotton, 25% rayon), creating a luxurious, vintage-inspired feel.

• Pros:
• Exceptionally soft with a silky, lightweight drape
• Offers a slightly worn-in, vintage aesthetic right from the start
• Resists shrinking and fading better than 100% cotton

• Breathable with moisture-wicking properties from polyester

• Cons:

• Higher price point due to premium materials
• May be less durable than 50/50 blends under heavy use

• Requires careful washing to maintain texture and shape

• Best For:
  Fashion-forward brands, high-end retail, or boutique-style tees; excellent for sublimation or soft-hand prints where a premium look and feel are key.

How to Choose the Right Fabric for Your Shop

• Consider Your Audience:
  Are they eco-conscious (cotton), budget-minded (50/50), or style-focused (tri-blend)?

• Think About Use Case:
  Promotional giveaways? Durable 50/50. Lifestyle brand? Luxe tri-blend. Classic everyday wear? 100% cotton.

• Evaluate Print Method:
  Some fabrics work better with certain inks or techniques—cotton excels with traditional screen printing, while tri-blends suit soft, distressed looks.

• Factor in Budget and Margins:
  Tri-blends cost more but allow for premium pricing; 50/50 blends offer value and reliability.

By aligning your fabric choice with your brand identity and customer expectations, you’ll create custom t-shirts that look great, feel comfortable, and keep customers coming back.

How to Get the Best Price on 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. To ensure you get the best possible price without sacrificing quality, it’s important to leverage quantity breaks and optimize your design process. Here’s how.

Understand Bulk Quantity Breaks

Most custom apparel suppliers offer tiered pricing based on order volume—known as quantity breaks. As your order size increases, the per-unit cost decreases significantly.

• Know the Thresholds: Common quantity break points include 50, 100, 250, and 500 units. Ordering just above a break (e.g., 101 instead of 99) can drastically lower your per-shirt cost.
• Plan for Growth: If you’re unsure about needing 250 shirts now, consider whether you’ll need them soon. It’s often cheaper to order more upfront than to reorder later.
• Mix Sizes, Not Styles: You can usually mix shirt sizes (S–XXL) within the same style and color to reach a quantity break. Avoid mixing different shirt styles or colors, as these often count as separate orders and may not qualify for the same discount.

Choose the Right Shirt Style and Brand

Not all t-shirts are priced equally. To reduce costs:

• Opt for Budget-Friendly Blends: 100% cotton or premium fabrics (like tri-blend) cost more. A standard 50/50 cotton-polyester blend often offers great quality at a lower price.
• Stick to Popular Brands: Suppliers often have volume discounts with brands like Gildan, Hanes, or Bella+Canvas. These are cost-effective and widely available.
• Limit Color Options: Ordering all shirts in one or two colors is cheaper than using multiple colors due to setup and inventory costs.

Optimize Your Artwork for Cost Efficiency

The design process can add unnecessary costs if not managed well. Follow these tips to save money:

• Simplify Your Design: Fewer colors and smaller print areas reduce screen setup and ink costs. A one- or two-color design is significantly cheaper than a full-color or multi-color print.
• Use Vector Art: Provide artwork in vector format (AI, EPS, or SVG) to avoid redraw fees. High-resolution PNG or PDF files are acceptable, but vendors may charge to convert or clean up pixelated images.
• Avoid All-Over Prints: Full-shirt or all-over sublimation printing is more expensive than standard front or back prints. Stick to single or double-sided standard prints when possible.
• Standard Print Locations: Chest prints, center back, or sleeve prints are cheaper than complex placements (e.g., under the sleeve or along the hem).

Get Multiple Quotes and Negotiate

Don’t settle for the first quote:

• Compare at Least 3 Suppliers: Online printers like Custom Ink, Printful, RushOrderTees, and local screen printers often have different pricing structures.
• Ask About Promo Codes and Discounts: Many vendors offer first-time buyer discounts, seasonal sales, or free shipping on bulk orders.
• Negotiate Based on Volume: If you’re ordering 500+ units, don’t hesitate to ask for a custom quote or additional discount—many suppliers are willing to work with you.

Final Tips for Maximum Savings

• Order Off-Peak: Avoid peak seasons (spring/summer) when demand is high. Ordering in fall or winter may get you better rates.
• Bundle with Other Items: Some suppliers offer discounts when you order matching hats, hoodies, or bags with your shirts.
• Review the Proof Carefully: Catching design errors early avoids costly reprints.

By leveraging bulk quantity breaks, simplifying your artwork, and smartly selecting materials and vendors, you can get high-quality custom t-shirts at the best possible price. Plan ahead, compare options, and communicate clearly with your supplier to maximize value.