Comparison of T-Shirt Custom Design Methods

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Choosing the Best Fabric for Your Custom T-Shirt Design

When creating custom t-shirts, selecting the right fabric is just as important as the design itself. The material affects comfort, durability, appearance, and how well your graphics print. Here’s a breakdown of the three most popular options: 100% cotton, 50/50 blends, and tri-blends.

100% Cotton

Pros:
– Soft and Breathable: Offers a classic, natural feel that’s ideal for warm weather and everyday wear.
– Excellent Printability: Provides a smooth, absorbent surface perfect for vibrant screen printing and direct-to-garment (DTG) printing.
– Eco-Friendly Option: Biodegradable and often available in organic varieties, appealing to environmentally conscious customers.

Cons:
– Prone to Shrinkage: May shrink up to 5–7% after washing if not pre-shrunk.
– Less Durable: Can wear out faster, especially after repeated washings.
– Wrinkles Easily: Requires ironing for a crisp look and tends to hold creases.

Best for: Casual wear, vintage-style designs, eco-focused brands, and customers who prefer a traditional cotton feel.

50/50 Blend (50% Cotton / 50% Polyester)

Pros:
– Reduced Shrinkage: More stable than 100% cotton, maintaining shape and size after washing.
– Durable and Resilient: Polyester adds strength, making the shirt more resistant to wear and fading.
– Affordable: Often less expensive than tri-blends, offering a budget-friendly option with good performance.

Cons:
– Less Breathable: Can feel warmer and less comfortable in hot climates due to reduced moisture absorption.
– Slightly Stiffer Feel: The polyester content can make the fabric feel less soft compared to pure cotton.
– Pilling: May develop small fabric balls over time with friction.

Best for: Promotional events, sports teams, workwear, and situations where durability and cost-efficiency are priorities.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon)

Pros:
– Ultra-Soft Texture: Combines the softness of cotton, durability of polyester, and drape of rayon for a luxurious, vintage feel.
– Excellent Drape: Flatters the body with a smooth, slightly fitted silhouette.
– Minimal Shrinkage: Very stable in the wash and retains shape well.
– Vintage Aesthetic: Ideal for retro or fashion-forward designs due to its heathered look and muted finish.

Cons:
– Higher Cost: Typically the most expensive of the three options.
– Sensitivity to Heat: Rayon can weaken under high heat, so low-temperature washing and drying are recommended.
– Less Absorbent: Not ideal for high-sweat activities due to reduced moisture-wicking compared to pure cotton.

Best for: Fashion apparel, boutique brands, lifestyle designs, and premium custom tees where comfort and style are key.

Final Tips for Choosing

• Consider the Use Case: Is the shirt for daily wear, athletic use, or promotional giveaways?
• Think About Your Design: Bold graphics pop on 100% cotton and 50/50 blends, while tri-blends enhance soft, artistic prints.
• Know Your Audience: Prioritize softness for lifestyle brands, durability for teams, and sustainability for eco-conscious markets.

By matching your fabric choice to your design goals and target audience, you’ll ensure your custom t-shirts not only look great but feel great too.

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

Ordering custom T-shirts in bulk can be a cost-effective way to promote your brand, event, or team—but only if you know how to maximize savings. Two key factors that significantly impact your bottom line are leveraging bulk quantity breaks and preparing print-ready artwork. Here’s how to get the best price without sacrificing quality.

Understand and Leverage Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order volume. The more shirts you order, the lower the per-unit cost. Here’s how to take full advantage:

• Know the Break Points: Common quantity breaks occur at 25, 50, 100, 250, and 500 units. For example, ordering 99 shirts might cost $10 each, but 100 could drop to $7.50. Always ask for the full pricing schedule before finalizing your order.

• Consolidate Designs: If you need multiple designs, see if you can combine them into one order. Some printers charge lower setup fees when multiple designs are printed together.

• Standardize Sizes and Colors: Ordering in a single shirt color and fewer size variations reduces setup and inventory complexity, often leading to lower costs.

• Choose Simpler Printing Methods: Screen printing is generally cheaper for large runs (100+ units), especially with fewer print colors. DTG is better for small runs or complex designs but costs more per shirt.

Optimize Your Artwork to Reduce Costs

High-quality artwork not only looks better but also reduces production issues and extra charges:

• Use Vector Files (AI, EPS, SVG): Vector graphics scale infinitely without losing quality, making them ideal for printing. This prevents pixelation and reduces the need for costly file corrections.

• Stick to Fewer Print Colors: Each additional color in screen printing requires a separate screen and setup. Simplifying your design to 1–3 colors can dramatically cut costs.

• Provide High-Resolution Raster Files (300 DPI): If you must use PNG or JPEG, ensure it’s at least 300 dpi at the intended print size (e.g., 10″x10″ at 300 dpi).

• Avoid Small Text and Fine Details: Tiny text or intricate lines may not print clearly, especially with screen printing. Simplify and enlarge key elements.

• Confirm Color Matching: Use Pantone (PMS) colors for brand consistency. Providing exact color codes avoids miscommunication and costly reprints.

Bonus Tips for Maximum Savings

• Compare Multiple Vendors: Get quotes from at least 3–5 reputable printers. Use the same specs to make comparisons accurate.

• Ask About Setup Fees and Minimums: Some vendors waive setup fees for large orders or offer discounts for repeat customers.

• Order Slightly More Than Needed: Running out and needing a small reorder is expensive. A 5–10% buffer is often cheaper than a second production run.

• Time Your Order: Avoid peak seasons (e.g., back-to-school, holidays) when demand is high and prices may rise.

By strategically using bulk quantity breaks and preparing professional artwork, you can dramatically reduce your custom T-shirt costs while ensuring a high-quality finished product. Plan ahead, communicate clearly with your printer, and always request a sample or proof before full production.