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

Choosing Fabrics for Screen Printed Custom T-Shirts: 100% Cotton vs. 50/50 Blend vs. Tri-Blend

When creating custom screen printed t-shirts, selecting the right fabric is crucial for both print quality and wearer comfort. The three most popular options—100% cotton, 50/50 cotton-polyester blend, and tri-blends—each offer distinct advantages and trade-offs. Understanding these differences will help you make the best choice for your project.

100% Cotton: Classic Comfort and Natural Feel

100% cotton t-shirts are a timeless favorite, prized for their softness, breathability, and natural feel against the skin.

Pros:
– Superior Softness: Feels comfortable and natural, especially after a few washes.
– Excellent Print Absorption: Cotton fibers absorb ink well, resulting in vibrant, crisp prints with rich color saturation.
– Breathable: Ideal for warm weather or active wear due to its moisture-wicking (though not as efficient as synthetics).
– Eco-Friendly: Biodegradable and often available in organic options.

Cons:
– Prone to Shrinking: Especially if not pre-shrunk; may shrink 3–5% after washing.
– Less Durable: More likely to wear out, pill, or fade over time with frequent washing.
– Wrinkles Easily: Requires ironing for a polished look.
– Holds Moisture: Can feel damp when sweaty since it retains moisture longer than synthetic blends.

Best For: Casual, vintage-style shirts, eco-conscious brands, or designs requiring bold, opaque ink coverage.

50/50 Cotton-Polyester Blend: The Balanced Performer

A 50% cotton and 50% polyester blend combines the best of both fibers—offering softness with enhanced durability.

Pros:
– Reduced Shrinkage: More stable than 100% cotton; maintains shape after washing.
– Durable & Long-Lasting: Resists pilling, fading, and wear better than pure cotton.
– Wrinkle-Resistant: Holds its shape and looks fresh longer.
– Lightweight & Affordable: Often less expensive than premium cotton or tri-blends.

Cons:
– Slightly Less Soft: Can feel a bit stiffer or less breathable than 100% cotton.
– Ink May Sit on Surface: Polyester doesn’t absorb ink as well, which can affect print vibrancy unless specialty inks (like high-opacity or discharge) are used.
– Less Eco-Friendly: Polyester is petroleum-based and not biodegradable.

Best For: Budget-friendly bulk orders, promotional apparel, workwear, or garments that require frequent washing.

Tri-Blend (Typically Cotton/Polyester/Rayon): Softness with a Vintage Drape

Tri-blend fabrics usually combine cotton, polyester, and rayon (often in a 50/25/25 ratio), creating a uniquely soft, lightweight, and slightly heathered look.

Pros:
– Exceptionally Soft: Often described as “buttery” or “vintage-soft” with a luxurious feel.
– Great Drape: Flatters the body with a slightly relaxed, flowy fit.
– Heathered Aesthetic: The blend naturally creates a marbled or heathered appearance, ideal for modern, fashion-forward styles.
– Fade-Resistant: Holds color well over time.

Cons:
– Delicate Fabric: Less durable than cotton or 50/50; can snag or thin with heavy use.
– Shrinking Risk: May shrink if not properly pre-treated or washed in hot water.
– Specialty Printing Needs: Requires careful ink selection (often water-based or discharge inks) for best results due to low cotton content.
– Higher Cost: Typically more expensive than basic cotton or 50/50 blends.

Best For: Fashion-forward apparel, boutique brands, women’s cuts, and soft-hand feel designs where comfort and aesthetics are top priorities.

Final Tips for Choosing the Right Fabric

• Consider Your Audience: Are they employees needing durable work shirts, or fashion-conscious customers wanting a premium feel?
• Think About Wash Frequency: High-use garments benefit from the durability of 50/50 or tri-blend.
• Match Ink to Fabric: Water-based inks work beautifully on cotton and tri-blends; plastisol is more versatile but may require adjustments on polyester-heavy fabrics.
• Always Test First: Print a sample on your chosen fabric to evaluate color, feel, and wash performance.

By weighing comfort, durability, print quality, and budget, you can confidently choose the ideal fabric—whether it’s the classic appeal of 100% cotton, the practicality of a 50/50 blend, or the luxurious softness of a tri-blend.

How to Get the Best Price for Screen-Printed Custom T-Shirts (Bulk Quantity Breaks, Artwork Tips)

Ordering custom screen-printed t-shirts in bulk can be a cost-effective way to promote your brand, event, or team. To get the best price without sacrificing quality, consider both bulk pricing strategies and artwork preparation. Here’s how:

Leverage Bulk Quantity Breaks

Screen printing becomes more affordable per unit as order quantities increase due to setup costs being spread across more items. Here’s how to maximize savings:

Order Larger Quantities

• Typical quantity breaks: 12, 24, 48, 72, 100, 250, 500+
• The more you order, the lower the per-unit cost. For example, 50 shirts might cost $10 each, while 250 could drop to $6 each.
• Tip: If you’re unsure about demand, consider ordering slightly more than needed—leftover shirts are often easier to repurpose than under-ordering and paying higher prices later.

Consolidate Designs

• Each unique design requires a separate setup (screens, alignment, etc.), which increases cost.
• Tip: Use the same design across multiple shirt colors instead of creating multiple designs—this reduces setup fees.

Limit Print Locations

• Each print location (front, back, sleeve) adds time and cost.
• Tip: Stick to one or two print locations to keep prices low. A single front print is usually the most economical.

Choose Simpler Ink Colors

• Standard ink colors (black, white, red, blue) are cheaper than specialty inks (metallic, glow-in-the-dark, puff).
• Tip: Use fewer ink colors in your design (1–3 colors) to reduce screen setup and printing time.

Optimize Your Artwork for Cost Efficiency

The complexity of your artwork directly affects printing cost and quality. Follow these tips to save money and ensure a great result:

Simplify Your Design

• Fewer colors = fewer screens = lower cost.
• Tip: Convert complex logos or images to 1–3 solid colors. Remove gradients and fine details that don’t translate well to screen printing.

Use Vector Art Files

• Provide artwork in vector format (AI, EPS, SVG) for crisp, scalable prints.
• Tip: Avoid low-resolution JPEGs or PNGs—they may require costly recreation by the printer.

Follow the Printer’s Guidelines

• Ask your printer for their artwork specifications (bleed, color mode, file type).
• Tip: Submit print-ready files to avoid extra fees for design adjustments.

Limit Color Overlaps and Underbasing

• Printing dark inks on dark shirts requires an underbase (usually white), which adds a step and cost.
• Tip: Choose shirt colors that complement your design to reduce the need for underprinting.

Additional Cost-Saving Tips

• Get multiple quotes: Compare pricing from 3–5 screen printing companies.
• Choose affordable blank shirts: Premium brands (e.g., Bella+Canvas) cost more. Consider value-priced blanks for large orders.
• Plan ahead: Rush orders often carry a 20–50% surcharge.
• Bundle with other items: Some printers offer discounts when ordering hoodies, hats, or tote bags with t-shirts.

By ordering in larger quantities, minimizing design complexity, and preparing print-ready artwork, you can significantly reduce the cost per shirt—making custom screen printing a smart investment for your needs.