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

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing the Perfect Fabric for a Custom T-Shirt

When ordering a single custom T-shirt, selecting the right fabric is crucial—it affects comfort, durability, print quality, and overall feel. The three most common options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s how to decide which is best for your needs.

100% Cotton: Classic Softness and Breathability

Best for: Everyday wear, soft hand-feel, eco-conscious buyers, screen printing (especially water-based inks)

• Pros:
• Naturally soft and breathable, ideal for warm weather
• Highly absorbent, great for moisture (though not technical performance)
• Excellent for detailed screen printing; holds ink well

• Biodegradable and generally more eco-friendly than synthetic blends

• Cons:

• Prone to shrinking (especially if not pre-shrunk)
• Less durable over time; may wear or pill with frequent washing
• Wrinkles and fades more easily than blended fabrics
• Can feel heavier, especially in heavier weights (e.g., 6 oz or more)

Ideal if: You want a classic, soft, natural-feeling T-shirt and don’t mind a bit of shrinkage or care.

50/50 Cotton-Polyester Blend: Durability Meets Comfort

Best for: Active use, promotional shirts, frequent washing, budget-friendly options

• Pros:
• Resists shrinking and wrinkling better than 100% cotton
• More durable and long-lasting
• Holds color well; great for vibrant DTG (direct-to-garment) prints
• Lightweight and slightly more moisture-wicking than cotton alone

• Often more affordable than premium cotton or tri-blends

• Cons:

• Less breathable than 100% cotton; can feel warmer
• Polyester may feel slightly synthetic or “plasticky” to some
• Not as soft initially (though it softens over time)
• Less eco-friendly due to synthetic content

Ideal if: You want a sturdy, low-maintenance shirt that will last through many washes—perfect for workwear, events, or gifts.

Tri-Blend (Usually 50% Poly, 25% Cotton, 25% Rayon): The Premium Soft Choice

Best for: Fashion-forward tees, ultra-soft comfort, vintage look, lightweight wear

• Pros:
• Exceptionally soft with a smooth, slightly drapey feel (often compared to vintage tees)
• Lightweight and breathable
• Resists shrinking and fading better than 100% cotton

• Offers a heathered, vintage aesthetic due to fiber blending

• Cons:

• More expensive than cotton or 50/50 options
• Rayon can be less durable and more prone to pilling or snagging
• May stretch out over time with heavy use
• Not ideal for high-heat printing methods; requires careful handling

Ideal if: You’re looking for a luxurious, soft, stylish shirt with a modern or retro vibe—great for fashion statements or special gifts.

How to Choose the Right One for Your Custom T-Shirt

• Want maximum softness and natural feel? → Go with 100% cotton (preferably ringspun or combed cotton).
• Need durability and easy care? → Choose a 50/50 blend.
• Craving a buttery-soft, fashion-forward tee? → Pick a tri-blend.

Also consider your printing method:
– Screen printing: 100% cotton or 50/50 blends work best.
– DTG printing: All three work, but 50/50 and tri-blends offer vibrant, long-lasting results.

Ultimately, your choice depends on how you plan to wear, wash, and enjoy your custom T-shirt. Each fabric has its strengths—pick the one that matches your priorities.

How to Get the Best Price on a Single Custom T-Shirt (Including Bulk Quantity Breaks & Artwork Tips)

While getting a single custom T-shirt made can be expensive, understanding pricing structures—especially bulk quantity breaks—and optimizing your artwork can help you save significantly, even if you start with one shirt. Here’s how to get the best deal.

Understand Bulk Quantity Breaks

Most screen printing and custom apparel companies offer tiered pricing based on how many shirts you order. The more you order, the lower the per-unit cost.

• Typical Quantity Tiers: Prices often drop at quantities like 12, 24, 48, 72, 100, and 250+ units.
• Example: A single shirt might cost $25, but ordering 24 could bring the price down to $8 per shirt.
• Strategy for Savings: Even if you only need one shirt now, consider teaming up with friends, family, or coworkers to combine orders. Split the cost and enjoy bulk pricing.

Order Now, Use Later

If you anticipate needing more shirts in the future (e.g., for events, promotions, or personal use), it’s smarter to order in bulk upfront.

• Storage Tip: Store extras in a cool, dry place to maintain quality.
• Future-Proofing: Save your design file and order details so reordering is simple and fast.

Optimize Your Artwork for Lower Costs

The complexity of your design directly impacts the price. Simplify to save.

• Limit Print Colors: Each additional color requires a separate screen and setup charge. Stick to 1–3 colors when possible.
• Use Vector Art: Submit artwork in vector format (e.g., .AI, .EPS, or .SVG) to avoid re-drawing fees. High-resolution PNGs (300 DPI) are acceptable but may incur extra prep charges.
• Avoid Gradients and Photo Effects: These often require simulated process printing, which is more expensive than standard screen printing.
• One-Location Printing: Printing on just the front (or just the back) is cheaper than multi-location designs.

Choose the Right Printer and Shirt Style

Not all printers or T-shirts are created equal—smart choices save money.

• Compare Quotes: Use online quote tools from multiple suppliers (like Custom Ink, RushOrderTees, or local screen printers) to find the best deal.
• Basic Shirt Options: Opt for budget-friendly, widely available styles (e.g., Gildan Softstyle, Hanes Beefy-T). Premium brands (e.g., Bella+Canvas) cost more.
• Ask About Setup Fees: Some companies waive setup/screen fees for larger orders or repeat customers.

Consider Alternative Printing Methods

For a single shirt, direct-to-garment (DTG) printing might be more cost-effective than screen printing.

• DTG Pros: No setup fees, ideal for complex or full-color designs on one or few shirts.
• DTG Cons: Higher per-shirt cost in bulk and less durability than screen printing.
• Best For: One-off or small runs with detailed artwork.

Final Tips for Maximum Savings

• Sign Up for Newsletters: Many companies offer first-order discounts or flash sales.
• Look for Promo Codes: Search online for current coupon codes before checking out.
• Time Your Order: Avoid peak holiday seasons when demand (and prices) are higher.

By leveraging bulk pricing, simplifying your design, and choosing the right printing method, you can drastically reduce the cost per custom T-shirt—even if you only need one today.