Comparison of T-Shirt Custom Printing Methods: Screen Printing, DTG, and Heat Transfer

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

When designing custom t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and print quality. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends will help you select the best option for your specific needs.

100% Cotton: Classic Comfort and Softness

100% cotton t-shirts are made entirely from natural cotton fibers, making them a timeless favorite for custom printing. They offer a soft, breathable feel that’s ideal for everyday wear.

Pros:
– Soft and comfortable, especially after a few washes
– Highly breathable, great for warm weather
– Absorbs ink well, resulting in vibrant, crisp prints
– Natural, eco-friendly material (especially if organic)

Cons:
– Prone to shrinking, especially if not pre-shrunk
– Can wrinkle easily
– Less durable over time; may thin or pill with frequent washing
– Heavier feel compared to blended fabrics

Best For: Casual wear, vintage-style designs, eco-conscious brands, and screen printing where vibrant colors are desired.

50/50 Cotton-Polyester Blend: Balanced Performance

A 50/50 blend combines equal parts cotton and polyester, offering a middle ground between natural softness and synthetic durability. This blend is popular for promotional and team apparel.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– More durable and long-lasting
– Lightweight with a slightly smoother texture
– Holds its shape well over time

Cons:
– Less breathable than 100% cotton
– Polyester can cause ink to sit on the surface, potentially reducing print vibrancy (may require pretreatment for screen printing)
– Slight synthetic feel compared to pure cotton

Best For: Workwear, giveaways, active environments, and designs requiring long-term durability. Ideal for direct-to-garment (DTG) printing with proper pretreatment.

Tri-Blend: Softness with a Fashion-Forward Feel

Tri-blend fabrics typically consist of cotton, polyester, and rayon (often in a 50%/25%/25% ratio). This combination creates a soft, lightweight fabric with a slightly heathered appearance and a vintage drape.

Pros:
– Exceptionally soft with a luxurious, silky feel
– Lightweight and drapes beautifully
– Resists shrinking and fading better than 100% cotton
– Offers a modern, stylish look popular in fashion-forward apparel

Cons:
– More expensive than cotton or 50/50 blends
– Rayon can be less durable and may require gentle washing
– Print colors may appear slightly muted due to the heathered base
– Not ideal for heavy ink coverage or opaque designs

Best For: Boutique brands, fashion tees, women’s fit styles, and designs aiming for a vintage or soft aesthetic. Works well with DTG printing.

Choosing the Right Fabric for Your Custom T-Shirt

Consider these factors when deciding:
– Intended Use: Is it for daily wear, events, or promotional giveaways?
– Comfort Preference: Do you prioritize softness, breathability, or durability?
– Print Quality: Vibrant colors favor 100% cotton; subtle, vintage looks suit tri-blends.
– Budget: Tri-blends are typically more expensive; 50/50 blends offer good value.
– Sustainability Goals: 100% organic cotton is the most eco-friendly option.

By matching your fabric choice to your design, audience, and purpose, you’ll create custom t-shirts that look great, feel comfortable, and stand the test of time.

How to Get the Best Price for Custom T-Shirt Printing (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 maximize savings and ensure high-quality results, focus on two key areas: leveraging bulk pricing and optimizing your artwork. Here’s how to get the best possible price.

Understand Bulk Quantity Breaks

Most print shops offer significant discounts as your order quantity increases. These are known as “quantity breaks.”

• Know the Tiers: Common bulk quantity tiers include 25, 50, 100, 250, and 500+ units. Prices per shirt often drop sharply at each tier.
• Order Just Above the Break: If the price per shirt drops at 100 units, ordering 101 shirts is often nearly the same cost as 100—but gives you an extra shirt. Avoid ordering just below a break (e.g., 99 when the break is at 100).
• Consolidate Orders: If you think you’ll need more shirts later, consider ordering a larger batch now to benefit from lower per-unit pricing.
• Compare Multiple Vendors: Different suppliers have different break points and rates. Get quotes from at least 3–5 reputable printers to find the best deal for your volume.

Choose the Right Printing Method

The printing technique significantly affects both price and quality. Match the method to your design and budget.

• Screen Printing: Best for large, simple designs with few colors. Cost decreases dramatically with bulk orders because setup costs are spread across more units.
• DTG (Direct-to-Garment): Ideal for detailed, full-color designs or small batches. More expensive per unit in bulk but great for complex artwork.
• Heat Transfer: Lower upfront cost, but less durable and not ideal for large quantities.
• For best bulk pricing, screen printing is usually the most economical choice—especially with 1–3 color designs.

Optimize Your Artwork for Cost Savings

Your design directly impacts printing costs. Smart artwork prep can reduce expenses.

• Limit Colors: Each additional color in screen printing requires a separate screen and setup. Stick to 1–3 colors to minimize costs.
• Use Vector Files: Provide artwork in vector format (AI, EPS, SVG). This ensures crisp, scalable prints and avoids extra fees for file conversion.
• Simplify the Design: Complex details or gradients may require more ink or a pricier method like DTG. Simplify to reduce production time and cost.
• Stick to Standard Print Areas: Large or multi-panel prints (e.g., full back, sleeves) increase ink use and time. Smaller, centered designs are cheaper.
• Avoid Photographic Prints in Screen Printing: High-detail images work better with DTG but cost more. For screen printing, opt for bold, flat-color graphics.

Additional Tips to Save Money

• Choose Standard Shirt Colors: White or neutral-colored shirts are typically cheaper than fashion or specialty colors.
• Select Basic Shirt Styles: Premium or branded blanks (e.g., Gildan Heavy Cotton vs. Bella+Canvas 3001) affect pricing. Balance quality with budget.
• Bundle Sizes and Colors: Some printers offer discounts if you order multiple colors or sizes within the same design.
• Ask About Setup Fees: Some vendors waive or reduce screen setup fees for larger orders. Negotiate or look for promo deals.
• Plan Ahead: Rush orders often incur fees. Place your order well in advance to avoid surcharges.

By understanding quantity breaks, selecting the right printing method, and preparing cost-effective artwork, you can significantly reduce your per-shirt cost while maintaining professional quality. Always request a physical or digital proof before full production to avoid costly mistakes.