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

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

Selecting the right fabric is crucial when designing custom t-shirts. The material affects not only how the shirt feels and wears but also how your design prints and holds up over time. Here’s a breakdown of three popular options: 100% Cotton, 50/50 Blend, and Tri-blends.

100% Cotton

Pros:
– Soft and Breathable: Offers a classic, comfortable feel that’s ideal for everyday wear, especially in warmer climates.
– Eco-Friendly: Natural fiber that is biodegradable and often preferred by environmentally conscious consumers.
– Excellent Print Quality: Absorbs ink well, providing vibrant, crisp results—especially with water-based and discharge inks.
– Easy to Decorate: Works seamlessly with screen printing, DTG (direct-to-garment), and heat transfer methods.

Cons:
– Prone to Shrinking: May shrink up to 5–7% if not pre-shrunk, especially after the first wash.
– Less Durable: More susceptible to pilling and wear over time compared to blended fabrics.
– Wrinkles Easily: Requires more care during washing and ironing.

Best For: Casual wear, vintage-style designs, eco-conscious brands, and high-quality screen or DTG printing.

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

Pros:
– Durable and Resilient: Polyester adds strength, helping the shirt resist shrinking, fading, and pilling.
– Minimal Shrinkage: Typically shrinks less than 3%, making sizing more consistent.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Cost-Effective: Often more affordable than 100% cotton or tri-blends.

Cons:
– Less Breathable: Polyester can trap heat, making it less comfortable in hot weather.
– Prone to Pilling: May develop small fabric balls over time, especially with friction.
– Ink Absorption: Polyester doesn’t absorb water-based inks as well, which can affect print softness (though plastisol ink works well).

Best For: Promotional shirts, workwear, events, or when durability and budget are top priorities.

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

Pros:
– Ultra-Soft Hand Feel: Combines the softness of cotton, the durability of polyester, and the drape of rayon for a luxurious, vintage-like texture.
– Excellent Drape: Flatters the body and moves naturally, great for fitted or fashion-forward styles.
– Fade-Resistant: Polyester content helps maintain color over time.
– Minimal Shrinkage: Pre-shrunk tri-blends offer consistent sizing.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends due to complex fabric composition.
– Sensitivity to Heat: Rayon can degrade under high heat, so lower heat settings are needed during printing and washing.
– Delicate Care: Requires gentle washing to maintain softness and structure.

Best For: Premium apparel, boutique brands, fashion-focused designs, and soft-hand screen or DTG printing.

Final Tips for Choosing

• Consider the Use Case: Is it for events, retail, or corporate gifts? Durability may trump softness—or vice versa.
• Think About Print Method: DTG works beautifully on cotton and tri-blends; plastisol ink is ideal for 50/50 blends.
• Know Your Audience: Younger audiences may prefer the soft drape of tri-blends, while corporate clients might value the durability of 50/50s.
• Order Samples: Always test print on actual fabric samples to assess look, feel, and wash durability.

By understanding the strengths and trade-offs of 100% cotton, 50/50 blends, and tri-blends, you can make an informed decision that ensures your custom t-shirts look great, feel comfortable, and last.

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

Getting custom t-shirts printed in bulk doesn’t have to break the bank. By understanding quantity breaks and optimizing your artwork, you can significantly reduce costs without sacrificing quality. Here’s how:

Leverage Bulk Quantity Breaks

Most printers offer tiered pricing, where the cost per shirt drops as your order size increases. Understanding and maximizing these breaks is key to saving money.

• Know the Thresholds: Ask potential printers for their exact quantity break points (e.g., 12, 24, 50, 100, 250, 500). Ordering just below a break point (e.g., 49 instead of 50) can mean paying a much higher unit cost.
• Aim for the Next Break: If you need 45 shirts, ordering 50 is often cheaper per shirt and gives you 5 extra shirts as backup or for future use. Calculate the total cost difference to confirm the savings.
• Consolidate Orders: Instead of placing multiple small orders, combine needs (e.g., for events, teams, or merchandise) into one larger order to hit a higher, more favorable pricing tier.
• Consider Future Needs: If you anticipate needing more shirts later (even months down the line), ordering a slightly larger quantity now for a better price per unit can be a smart investment. Store extras properly.

Optimize Your Artwork for Lower Costs

Artwork complexity directly impacts printing costs, especially with screen printing. Simplifying your design can lead to substantial savings.

• Minimize Print Colors: Each additional ink color requires a separate screen, setup time, and labor. Stick to 1-3 colors whenever possible. Use simulated process or halftones strategically instead of solid spot colors for gradients.
• Simplify the Design: Avoid intricate details, fine lines, or tiny text that require precise screens and can increase setup time and potential for errors (leading to waste). Bold, clean designs are cheaper and often more impactful.
• Choose the Right Print Type: Match your artwork to the most cost-effective method:
  • Screen Printing: Best for simple designs with few colors on cotton/poly blends. Cheapest per unit for large runs.
  • DTG (Direct-to-Garment): Better for complex, full-color designs or photos on small runs. Higher per-shirt cost, but no setup fees for multi-color designs.
  • Heat Transfer: Often higher cost per unit and less durable, but good for very small quantities or specific effects. Avoid for large bulk orders seeking durability.
• Provide Print-Ready Files: Supply high-resolution (300 DPI), vector artwork (AI, EPS, SVG) or high-res PNG/PDF with transparent backgrounds. Clear, correctly formatted files prevent costly corrections, delays, and reprints.
• Limit Print Locations: Printing on just the front (or front and back) is cheaper than adding sleeves, pockets, or multiple panels. Each location adds setup and printing time.

Additional Cost-Saving Strategies

• Choose Standard Garments: Opt for popular, in-stock blank t-shirt brands and styles (e.g., Gildan, Hanes, Bella+Canvas 3001). Premium or specialty blanks cost more.
• Stick to Standard Sizes: Avoid excessive size splits (e.g., 1 of each size from XS to 4XL). Grouping sizes (e.g., 12 S/M, 12 L/XL) can sometimes streamline printing, though quantity breaks are usually based on total units.
• Get Multiple Quotes: Don’t settle for the first quote. Request detailed quotes from 3-5 reputable printers, ensuring they quote the same specs (garment, quantity, print colors, locations, ink types). Compare total cost and turnaround time.
• Ask About Setup Fees (Screens): For screen printing, understand the screen setup fee per color. Negotiate lower setup fees for very large runs or repeat orders. Some printers offer “free screens” on large orders.
• Plan Ahead: Rush orders incur significant premiums. Allow ample production and shipping time (4-6 weeks is common) to avoid expedited fees.
• Consider All-Inclusive Quotes: Ensure quotes include the blank shirt cost, printing, setup fees, tax, and shipping. Hidden costs add up.

By strategically using bulk quantity breaks and creating artwork designed for efficient production, you can achieve significant savings on your custom t-shirt printing project while still getting great quality.