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

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

When customizing t-shirts, the fabric you choose plays a crucial role in 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 selection for your project. Here’s a breakdown to guide your decision:

100% Cotton

What it is: Made entirely from natural cotton fibers.

Pros:
– Soft and breathable: Offers excellent comfort, especially in warmer weather.
– Eco-friendly appeal: Biodegradable and often preferred by environmentally conscious customers.
– Great for printing: Absorbs ink well, producing vibrant, crisp designs—ideal for screen printing and DTG (direct-to-garment).
– Classic feel: Delivers the traditional t-shirt experience many people love.

Cons:
– Prone to shrinking: May shrink after washing, especially if not pre-shrunk.
– Less durable: Can wear out faster and may pill over time with frequent use and washing.
– Wrinkles easily: Requires ironing for a smooth look.

Best For: Casual wear, vintage-style tees, eco-conscious brands, and designs that require high ink saturation.

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

What it is: A balanced mix of cotton and polyester fibers.

Pros:
– Durable and long-lasting: Resists wear and tear better than 100% cotton.
– Minimal shrinking: Holds its shape well over time.
– Wrinkle-resistant: Requires less ironing and maintains a neat appearance.
– Affordable: Often priced lower than high-end tri-blends.

Cons:
– Less breathable: Polyester can trap heat, making it less ideal for hot climates.
– Slight sheen: May have a slightly synthetic look compared to pure cotton.
– Ink absorption: Not as absorbent as cotton, which can affect print softness—though still suitable for most printing methods.

Best For: Workwear, promotional giveaways, active environments, and budget-friendly custom apparel with a balance of comfort and durability.

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

What it is: A luxurious combination of polyester, cotton, and rayon (often from bamboo or viscose).

Pros:
– Ultra-soft feel: Has a buttery, vintage drape that’s highly desirable.
– Excellent drape: Flatters the body and moves with the wearer.
– Reduced shrinkage: More stable than 100% cotton.
– Color retention: Holds dye and prints beautifully, with a slightly muted, retro aesthetic.

Cons:
– Higher cost: Typically more expensive than cotton or 50/50 options.
– Less breathable than cotton: Rayon and polyester reduce airflow.
– Delicate care: May require gentler washing to maintain softness and shape.

Best For: Premium apparel, fashion-forward designs, boutique brands, and customers seeking a soft, lived-in look with modern comfort.

How to Choose the Right Fabric

• Prioritize comfort and breathability? → 100% Cotton
• Need durability and cost-efficiency? → 50/50 Blend
• Want luxury softness and a vintage aesthetic? → Tri-Blend

Consider your audience, use case, printing method, and brand values when selecting the ideal fabric. Offering a variety of fabric options in your customizer can cater to diverse customer preferences and elevate your product offerings.

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

Getting custom t-shirts for your team, event, or business doesn’t have to break the bank. By leveraging bulk pricing and optimizing your artwork, you can achieve significant savings without sacrificing quality. Here’s how:

Understand Bulk Quantity Breaks

Most custom t-shirt printers offer tiered pricing based on order volume. The more you order, the lower the cost per shirt. Knowing how these breaks work is key to maximizing savings.

• Know the Thresholds: Printers typically have quantity tiers (e.g., 25, 50, 100, 250+ units). Prices drop significantly at each breakpoint. For example, ordering 99 shirts costs more per unit than ordering 100.
• Order Just Over the Breakpoint: If you need 80 shirts, consider jumping to 100. The per-unit cost could be 20–30% lower, making the extra 20 shirts a smart investment.
• Consolidate Designs: Instead of multiple small runs, combine designs into one larger order. Even if designs differ slightly, grouping them under one order often qualifies for bulk pricing.
• Plan Ahead: Anticipate future needs. Ordering extra now for later use can save money compared to placing multiple small orders.

Optimize Your Artwork for Lower Printing Costs

The complexity of your design directly impacts pricing. Simplifying artwork reduces setup and printing fees.

• Limit Print Colors: Each color added to a design requires a separate screen and setup fee. Stick to 1–3 colors for significant savings.
• Use Vector Files: Provide artwork in vector format (AI, EPS, SVG). Vector graphics scale without quality loss and are easier for printers to use, reducing prep time and cost.
• Simplify the Design: Avoid intricate details, gradients, or photorealistic images. Bold, clean graphics with solid colors are cheaper and more durable.
• Choose the Right Print Method:
• Screen Printing: Best for large quantities and simple designs. Lower per-unit cost with higher upfront setup.
• DTG (Direct-to-Garment): Cost-effective for small runs or complex designs, but higher per-shirt cost.
• Heat Transfer: Good for small orders, but less durable and costlier per unit than screen printing for bulk.
• Minimize Print Locations: Printing on just the front or back is cheaper than front and back. Each additional print location adds cost.

Additional Tips for Saving Money

• Choose Standard Shirt Colors: White or basic colors (black, navy, gray) are cheaper than fashion or neon colors.
• Buy Blank Shirts in Bulk: If you’re doing frequent custom runs, consider purchasing blank shirts ahead of time at wholesale prices.
• Compare Multiple Vendors: Get quotes from several printers. Some specialize in low minimums, others in high-volume discounts.
• Ask About Discounts: Inquire about seasonal promotions, nonprofit discounts, or loyalty programs.

By understanding quantity breaks and preparing print-ready artwork, you can get high-quality custom t-shirts at the best possible price—without compromising your vision.