Comparison of T-Shirt Custom Printing Methods

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

Selecting the right fabric for your custom printed T-shirts is crucial—it affects comfort, durability, print quality, and overall customer satisfaction. Here’s a breakdown of the three most popular fabric options to help you make the best choice for your project.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural feel, ideal for warm weather and everyday wear.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.
– Great Print Surface: Holds vibrant, detailed screen prints and direct-to-garment (DTG) inks exceptionally well.
– Classic Feel: The go-to choice for a traditional, comfortable T-shirt experience.

Cons:
– Less Durable: Prone to shrinking (especially if not pre-shrunk) and may wear out faster with heavy use.
– Wrinkles Easily: Requires more ironing or steaming to maintain a crisp look.
– Absorbs Moisture: Can feel heavy when sweaty and takes longer to dry.

Best For: Casual wear, retail apparel, promotional giveaways, and designs requiring bold, high-detail prints.

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

Pros:
– Durable and Long-Lasting: Resists shrinking, pilling, and fading better than 100% cotton.
– Wrinkle-Resistant: Maintains shape and appearance after washing.
– Affordable: Often more budget-friendly than tri-blends or premium cotton.
– Good Print Compatibility: Works well with screen printing and DTG, especially for bold designs.

Cons:
– Slightly Less Soft: Can feel coarser or less breathable than 100% cotton.
– Less Eco-Friendly: Polyester is a synthetic fiber derived from petroleum.
– Prone to Pilling Over Time: Especially after repeated washings.

Best For: Workwear, school events, sports teams, and bulk orders where durability and cost are top priorities.

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

Pros:
– Ultra-Soft and Lightweight: Offers a smooth, luxurious feel with a slight drape—almost like a vintage tee.
– Excellent Drape and Fit: Drapes beautifully on the body, ideal for fashion-forward styles.
– Color-Rich Prints: Perfect for DTG printing—inks appear vibrant and soft to the touch.
– Shrink-Resistant: Holds its shape well after washing.

Cons:
– Higher Cost: Generally more expensive than cotton or 50/50 blends.
– Less Breathable: Polyester and rayon content can retain heat.
– Delicate Fabric: May be prone to snagging or pilling with rough use.

Best For: Fashion apparel, boutique brands, premium giveaways, and soft-hand feel designs with photographic or detailed prints.

Choosing the Right Fabric for Your Needs

• Prioritize Comfort & Sustainability? → Go with 100% Cotton
• Need Durability & Budget Control? → Choose 50/50 Blend
• Want Premium Feel & Modern Look? → Opt for Tri-Blend

Consider your audience, intended use, print method, and budget when making your decision. Testing samples of each fabric with your actual design is always recommended to see how colors and textures appear in real life.

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

Ordering custom t-shirts in bulk is a great way to save money, but getting the best price requires strategy. By leveraging quantity breaks and optimizing your artwork, you can significantly reduce your per-unit cost without sacrificing quality.

Understand and Maximize Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) companies offer tiered pricing based on order size—known as quantity breaks. To get the best deal:

• Know the Break Points: Common breaks occur at 25, 50, 100, 250, and 500 units. Prices drop significantly at each threshold. For example, 49 shirts might cost $10 each, while 50 shirts cost $7 each.
• Order Just Above the Break: If you need 45 shirts, ordering 50 could lower your total cost due to the reduced per-unit price. Calculate the total spend to ensure it’s still a win.
• Combine Orders: If you’re part of a group, team, or organization, pool orders together to hit higher quantity tiers.
• Choose Simpler Designs for Large Runs: For orders over 100 units, screen printing becomes more cost-effective than DTG. Stick to designs with fewer colors to reduce printing costs.

Optimize Your Artwork for Lower Printing Costs

The design plays a huge role in your final price. Follow these tips to keep costs down:

• Limit Print Colors: Each additional color in screen printing requires a separate screen and setup fee. Stick to 1–3 colors for the best pricing.
• Use Vector Files (AI, EPS, SVG): These scalable files ensure crisp printing and are preferred by printers. Avoid low-resolution JPEGs or PNGs.
• Simplify Your Design: Remove unnecessary details, gradients, or tiny text that require higher ink density or multiple passes. Simpler = cheaper.
• Stick to One Print Location: Printing on the front only is less expensive than front + back or sleeves. Choose the most visible location wisely.
• Avoid Photo-Realistic Designs for Large Batches: These typically require DTG or full-color process printing, which is costlier than traditional screen printing. For large runs, consider stylized or simplified versions.

Additional Tips for the Best Deal

• Choose Standard Shirt Colors: White or solid-color shirts are cheaper than specialty or fashion colors.
• Buy Blank Shirts in Bulk: If you’re tech-savvy, buy blanks wholesale and hire a local printer only for printing—sometimes this combo is cheaper.
• Compare Multiple Quotes: Use online quoting tools from 3–5 reputable suppliers. Pay attention to setup fees, ink colors, and shipping.
• Plan Ahead: Rush orders often include a 20–50% markup. Place your order with plenty of lead time.
• Ask About Package Deals: Some printers offer discounts for repeat customers or bundled services (e.g., design + printing).

By combining smart ordering tactics with print-friendly artwork, you’ll maximize your budget and get high-quality custom t-shirts at the lowest possible price.