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

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

When designing custom t-shirts, the fabric you choose impacts comfort, durability, print quality, and overall wearability. Understanding the differences between popular options—100% cotton, 50/50 blends, and tri-blends—helps you make the best choice for your needs.

100% Cotton: Classic Comfort and Breathability

100% cotton t-shirts are a timeless favorite. Made entirely from natural cotton fibers, they offer softness, breathability, and excellent moisture absorption.

Pros:
– Naturally soft and comfortable, especially after washing
– Highly breathable—great for warm weather
– Excellent for screen printing and DTG (direct-to-garment) printing
– Absorbs dyes well, resulting in vibrant prints
– Biodegradable and eco-friendly (depending on sourcing)

Cons:
– Prone to shrinking, especially if not pre-shrunk
– Less durable than blended fabrics; may wear out faster
– Can wrinkle easily and lose shape over time
– May feel heavier, particularly in thicker weights (e.g., 6 oz)

Best For: Everyday wear, promotional giveaways, eco-conscious brands, and designs with detailed or colorful prints.

50/50 Blend: The Balanced Choice

A 50/50 blend combines 50% cotton and 50% polyester. This mix balances the comfort of cotton with the performance of polyester, making it a popular mid-range option.

Pros:
– Resists shrinking and wrinkling better than 100% cotton
– Lightweight and durable
– Holds its shape longer
– Slightly more moisture-wicking than cotton
– Often more affordable than premium fabrics

Cons:
– Less breathable than pure cotton
– Can feel slightly synthetic or less soft to some wearers
– Prints may not be as vibrant as on 100% cotton (especially with DTG)
– Polyester can pill over time

Best For: Active environments, budget-friendly apparel, school events, and casual workplace wear. Ideal when durability and cost are priorities.

Tri-Blends: Softness and Style

Tri-blend fabrics typically consist of 50% polyester, 25% cotton, and 25% rayon (viscose). This combination creates a uniquely soft, drapey, and vintage-feel fabric.

Pros:
– Exceptionally soft with a luxurious hand-feel
– Excellent drape—flattering fit and comfortable movement
– Resists pilling and shrinking better than 100% cotton
– Slightly moisture-wicking and quick-drying
– Achieves a trendy, heathered look naturally

Cons:
– More expensive than cotton or 50/50 blends
– Not as breathable as 100% cotton
– May require special care (gentle wash, low heat drying)
– Not ideal for high-contrast or highly detailed prints due to heathered base

Best For: Fashion-forward designs, boutique brands, women’s tees, and specialty apparel where softness and aesthetic appeal are key.

Final Tips for Choosing Your Fabric

• Consider the end use: Will the shirt be worn daily, for events, or as fashion apparel?
• Think about print method: DTG and screen printing perform differently on each fabric.
• Factor in budget: Tri-blends are premium; 50/50 blends offer value; cotton is mid-range.
• Prioritize comfort vs. durability: Cotton breathes best; polyester adds strength.
• Check garment weight: Measured in ounces per square yard (e.g., 4.5 oz, 6.1 oz). Lighter weights suit tri-blends and casual wear; heavier weights offer structure and durability.

By matching your fabric choice to your design goals, audience, and budget, you’ll create custom t-shirts that look great and feel even better.

How to Get the Best Price on Custom T-Shirt Designs (Bulk Discounts & Artwork Tips)

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, team, or event—but only if you approach it strategically. By leveraging quantity breaks and preparing professional artwork, you can significantly reduce your per-unit cost while ensuring high-quality results.

Understand and Leverage Bulk Quantity Breaks

Most print shops offer tiered pricing based on order volume. The more shirts you order, the lower your cost per shirt. Here’s how to maximize savings:

• Know Standard Quantity Tiers: Common bulk breaks include 25, 50, 75, 100, 250, and 500+ units. Always ask for a pricing sheet to compare costs across tiers.
• Order Just Above the Break Point: If 50 shirts cost $10 each and 75 cost $8 each, ordering 75 may save more overall—even if you don’t need that many.
• Consolidate Designs: Instead of ordering 3 designs at 25 units each, combine them into a single design at 75 units to hit a lower price tier.
• Negotiate Larger Orders: For 250+ units, ask about wholesale pricing or custom quotes—many suppliers offer special rates for large-volume customers.

Optimize Your Artwork to Reduce Printing Costs

The design you provide directly impacts production costs. Follow these tips to ensure your artwork is print-ready and budget-friendly:

• Use Vector Files (AI, EPS, SVG): Vector graphics scale infinitely without losing quality—essential for crisp prints. Avoid low-resolution JPEGs or PNGs.
• Simplify Your Design: Fewer colors = lower printing costs. Screen printing charges per color, so limit your palette (1-3 colors ideal).
• Avoid Gradients and Complex Effects: These can require simulated printing methods or DTG (Direct-to-Garment), increasing costs. Stick to solid fills when possible.
• Specify Pantone (PMS) Colors: For brand consistency, provide exact color codes. This avoids guesswork and reprints.
• Provide Proper File Setup: Include bleed (0.125”), safe margins, and transparent backgrounds. Label layers clearly if submitting multi-color designs.

Additional Tips for Best Pricing

• Choose Affordable Garment Styles: Basic cotton tees (e.g., Gildan 5000) are cheaper than premium brands (e.g., Bella+Canvas 3001).
• Limit Print Locations: Printing on one side (front only) is less expensive than front and back.
• Compare Multiple Suppliers: Get quotes from at least 3 reputable printers—local shops, online services (like Printful, RushOrderTees, or Custom Ink).
• Time Your Order: Avoid peak seasons (spring/summer) and rush fees by ordering well in advance.

By combining smart bulk ordering with print-ready artwork, you’ll achieve professional-quality custom t-shirts at the lowest possible price.