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

100% Cotton vs. 50/50 Blend vs. Tri-blends: Choosing the Best Fabric for Custom T-Shirts

When customizing t-shirts, the fabric you choose impacts comfort, durability, print quality, and overall customer satisfaction. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you make the best choice for your needs.

100% Cotton

Pros:
– Soft and breathable: Ideal for warm weather and sensitive skin.
– Eco-friendly: Natural fiber that’s biodegradable.
– Absorbs ink well: Provides vibrant, crisp prints with screen printing and direct-to-garment (DTG) methods.
– Classic feel: Offers that traditional, broken-in t-shirt experience.

Cons:
– Prone to shrinking: Especially if not pre-shrunk or washed in hot water.
– Less durable: More likely to wear thin or pill over time.
– Wrinkles easily: Requires more care when washing and storing.
– Can stretch out: Loses shape with heavy use or improper washing.

Best For: Casual wear, promotional giveaways, eco-conscious brands, and customers who prefer a natural, soft-hand feel.

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

Pros:
– Durable and resistant to wear: Withstands frequent washing and daily use.
– Less shrinkage: Polyester adds stability, reducing shrink compared to 100% cotton.
– Affordable: Often less expensive than tri-blends.
– Good print surface: Works well with most printing techniques, including vinyl and DTG.

Cons:
– Less breathable: Can feel warmer than 100% cotton.
– Slight synthetic feel: May not have the same softness as pure cotton.
– Pilling over time: Especially in high-friction areas.

Best For: Active environments, workwear, school uniforms, or when budget and durability are top priorities.

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

Pros:
– Ultra-soft and luxurious feel: Often described as “buttery” or “vintage-soft.”
– Excellent drape: Flatters the body with a slightly more tailored appearance.
– Resistant to shrinking and wrinkling: Maintains shape and appearance after washes.
– Great for detailed prints: Smooth surface enhances photo-quality DTG printing.

Cons:
– Higher cost: Usually the most expensive option.
– Less absorbent: May not hold ink as deeply as 100% cotton, affecting print longevity.
– Less durable in high-stress areas: Can be prone to runs or tears if snagged.

Best For: Premium apparel, fashion-forward designs, boutique brands, or when softness and aesthetics are key.

Final Tips for Choosing

• Consider the end use: Is it for daily wear, sports, or a high-end gift?
• Think about print method: DTG works well on all three, but cotton absorbs best; vinyl adheres better to polyester-rich fabrics.
• Factor in care instructions: Tri-blends and 50/50 blends are low-maintenance; cotton may require gentler handling.
• Know your audience: Some customers prefer natural fibers, while others value durability and ease of care.

By matching fabric type to 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-Shirts (Bulk Quantity Breaks & Artwork Tips)

Ordering custom t-shirts in bulk can be cost-effective, but to truly get the best price, you need to understand quantity breaks, optimize your artwork, and make smart sourcing decisions. Here’s how to save money without sacrificing quality.

Understand Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on the number of units ordered. These are called “quantity breaks.”

• Typical Quantity Tiers: Common breaks include 25, 50, 75, 100, 250, and 500+ units.
  Example: 25 shirts might cost $10 each, while 100 shirts drop to $6 each—a 40% savings.

• Maximize Your Order Size: If you’re close to the next tier (e.g., ordering 90 shirts), consider increasing your order to 100 to unlock lower per-unit pricing.

• Consolidate Orders: Team up with others (e.g., coworkers, club members, event groups) to meet higher quantity thresholds and share savings.

Choose the Right Printing Method

Different printing techniques affect cost and quality. Select the best one for your design and budget.

• Screen Printing: Most cost-effective for large orders (50+ units) with simple designs (1–5 colors). Setup costs are high, but per-unit cost drops significantly with volume.

• DTG (Direct-to-Garment): Better for complex, full-color designs or small runs. Higher per-unit cost, but no setup fees. Less cost-efficient at scale.

• Embroidery: Ideal for logos on polo shirts or hats. Pricing depends on stitch count—simpler designs save money.

Simplify Your Artwork to Reduce Costs

Design complexity directly impacts printing expenses.

• Limit Print Colors: Each additional color in screen printing increases setup and labor costs. Stick to 1–3 colors when possible.

• Use Vector Art: Provide artwork in vector format (AI, EPS, SVG) to avoid extra prep fees. Raster images (JPEG, PNG) may require redrawing.

• Optimize Design Placement: Printing on one location (e.g., center chest) is cheaper than multiple locations (front and back).

• Avoid Halftones and Gradients: These require special screens and can increase production time and cost. Use solid colors instead.

Select Affordable, High-Quality Blank T-Shirts

The shirt itself is a major cost factor.

• Choose Budget-Friendly Brands: Gildan, Hanes, and Bella+Canvas offer quality at lower price points. Premium brands (e.g., American Apparel) cost more.

• Stick to One Style and Color: Ordering multiple shirt styles or colors increases setup time and minimums per variation.

• Consider Fabric Weight and Fit: Lightweight 5.3 oz shirts are cheaper than heavyweight 6+ oz options. Unisex fits are typically less expensive than fashion cuts.

Get Multiple Quotes and Negotiate

• Request Quotes from 3–5 Suppliers: Compare pricing, setup fees, turnaround time, and shipping.

• Ask About Hidden Fees: Clarify costs for setup, screens, art correction, and shipping before ordering.

• Negotiate for Larger Orders: If ordering 200+ units, ask for a custom quote. Many suppliers offer discounts beyond standard tiers.

Time Your Order Strategically

• Avoid Rush Fees: Standard production is cheaper. Rush orders can add 25–50% to your cost.

• Order Off-Season: Some suppliers offer promotions during slower months (e.g., late winter).

Final Tips for Maximum Savings

• Order a Few Extra Shirts: It’s often cheaper to order 105 shirts instead of 100 if you anticipate needing extras. Reordering later incurs setup fees again.

• Use Mockups to Approve Designs: Avoid costly reprints by approving digital proofs first.

• Build a Relationship with a Supplier: Repeat orders can lead to loyalty discounts and better pricing over time.

By leveraging bulk quantity breaks, simplifying artwork, and choosing the right materials and methods, you can significantly reduce the cost of custom t-shirts—without compromising on quality.