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

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

When ordering custom t-shirts on a budget, fabric choice plays a huge role in comfort, durability, and overall appearance. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends helps you get the best value without sacrificing quality. Here’s a breakdown to guide your decision:

100% Cotton: Classic Comfort, Prone to Shrinkage

Pros:
– Soft and breathable: Offers excellent comfort, especially in warm weather.
– Natural feel: Loved for its traditional, soft hand-feel.
– Great for printing: Holds screen prints and DTG (direct-to-garment) inks well, producing vibrant colors.
– Biodegradable: An eco-friendly option at end of life.

Cons:
– Shrinks more: Can shrink up to 5–7% after washing, especially if not pre-shrunk.
– Less durable: More prone to pilling and wear over time, especially with frequent washing.
– Wrinkles easily: Requires ironing for a crisp look.
– Heavier feel: Some budget 100% cotton tees can feel thick or stiff.

Best For: Casual events, promotional giveaways, or when a natural cotton feel is a top priority.

50/50 Blend (50% Cotton / 50% Polyester): Budget-Friendly Durability

Pros:
– Resists shrinkage: Holds its shape better than 100% cotton.
– More durable: Withstands repeated washing without significant pilling.
– Affordable: Often one of the cheapest quality options for bulk custom orders.
– Lightweight: Slightly softer drape than basic cotton, with less stiffness.

Cons:
– Less breathable: Polyester can trap heat, making it less ideal for hot climates.
– Not as soft: Can feel slightly synthetic compared to pure cotton.
– Print quality variation: May require different inks or settings for optimal print results.

Best For: High-volume orders like corporate events, school fundraisers, or athletic teams where durability and cost are key.

Tri-Blend (Typically 50% Polyester / 25% Cotton / 25% Rayon): Premium Softness on a Budget

Pros:
– Ultra-soft feel: Often described as “buttery” or “vintage-soft” right from the start.
– Excellent drape: Flattering fit with a slightly relaxed, modern look.
– Minimal shrinkage: Retains shape and size better than cotton-only shirts.
– Great for fashion-forward designs: Ideal for lifestyle brands or boutique-style merch.

Cons:
– Higher cost: Usually more expensive than 100% cotton or 50/50 blends.
– Less durable over time: Rayon can weaken with frequent washing.
– Special care needed: May require gentle washing to maintain softness and prevent pilling.

Best For: Trendy apparel, boutique brands, or when softness and style are worth a slight price bump.

Final Tips for Choosing Cheap Custom T-Shirt Fabrics

• Prioritize your needs: Value comfort? Choose cotton. Need durability and low cost? Go 50/50. Want softness and style? Consider tri-blend.
• Check fabric weight: Lightweight (4.0–5.0 oz) is great for printing and layering; heavier (6.0+ oz) feels more substantial but may be warmer.
• Ask about pre-shrinking: Especially important with 100% cotton to avoid customer complaints.
• Order samples: Always test print quality and feel before bulk ordering.

By matching the fabric to your event, audience, and budget, you can create custom t-shirts that look great and feel comfortable—without overspending.

How to Get the Best Price on Custom T-Shirts in Bulk

Ordering custom T-shirts in bulk can be a cost-effective way to promote your brand, organize events, or sell merchandise. To get the best price without sacrificing quality, follow these proven strategies focused on bulk pricing, order optimization, and artwork tips.

Leverage Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing based on order size. The more shirts you order, the lower the per-unit cost.

• Order in larger quantities: Aim for minimums like 50, 100, or 250 units to access significant discounts.
• Compare quantity tiers: Request quotes for 50, 100, and 250+ units to see where the biggest price drops occur.
• Combine orders: If possible, coordinate with others (teams, clubs, or departments) to meet higher volume thresholds.

Choose Affordable Shirt Styles

Not all T-shirts are created equal—basic styles from trusted brands (like Gildan, Hanes, or Bella+Canvas) offer the best value.

• Stick to standard cotton: 100% cotton or cotton/poly blends are usually cheaper than premium or eco-friendly fabrics.
• Avoid specialty cuts: Unisex and standard fit shirts are typically less expensive than fitted, organic, or performance styles.

Minimize Print Complexity

Printing cost is influenced by the number of colors, print locations, and design size.

• Use 1–2 ink colors: Each additional color increases setup and printing time. Stick to simple, bold designs.
• Limit print areas: Printing on just the front reduces cost compared to front and back or sleeve prints.
• Avoid gradients and halftones: These require advanced techniques (like simulated process printing), which raise prices.

Optimize Artwork for Production

A well-prepared design saves time and money during the printing process.

• Submit vector files: Use AI, EPS, or SVG formats for crisp, scalable artwork. Avoid low-res JPEGs or PNGs.
• Outline text and logos: Convert fonts to outlines to prevent compatibility issues.
• Stick to Pantone (PMS) colors: This ensures color accuracy and reduces ink mixing fees.
• Keep it simple: Bold, high-contrast designs reproduce better and require less ink.

Get Multiple Quotes

Don’t settle for the first vendor you find. Compare prices and services from several providers.

• Use online quote tools: Many printers offer instant bulk pricing calculators.
• Ask about hidden fees: Confirm if setup, screens, or art prep are included.
• Consider local vs. online: Local shops may offer faster turnaround; online services often have lower base prices.

Plan Ahead to Avoid Rush Fees

Rush orders can add 20–50% to your total cost.

• Place orders early: Give yourself 2–4 weeks for production and shipping.
• Schedule around peak seasons: Avoid holidays or event months when demand (and prices) spike.

Reuse Screens for Future Orders

If you plan to reorder, ask your printer to store screens.

• Save on setup costs: Reusing screens can eliminate or reduce setup fees on repeat orders.
• Maintain consistency: Ensures your design stays identical across batches.

By combining smart ordering practices, design simplicity, and strategic vendor selection, you can achieve high-quality custom T-shirts at the lowest possible price—perfect for bulk needs on a budget.