Comparison of T-Shirt Custom Design Methods

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

When designing custom t-shirts, the fabric you choose impacts comfort, durability, appearance, and print quality. Understanding the key differences between 100% cotton, 50/50 blends, and tri-blends will help you select the perfect material for your project.

100% Cotton

Pros:
– Soft and Breathable: Naturally comfortable, especially in warm weather.
– Eco-Friendly: Biodegradable and often preferred for sustainable apparel.
– Great for Printing: Holds ink well, making it ideal for detailed screen printing and vibrant designs.
– Classic Feel: Offers a traditional t-shirt texture that many customers love.

Cons:
– Prone to Shrinking: May shrink if not pre-shrunk or washed improperly.
– Less Durable: Can wear out faster and develop pilling over time.
– Wrinkles Easily: Tends to crease and lose shape with repeated washing.
– Absorbs Moisture: Holds sweat, which may feel damp during physical activity.

Best For: Casual wear, eco-conscious brands, vintage-style tees, and screen-printed designs with bold colors.

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

Pros:
– Durable and Resilient: Resists shrinking, fading, and pilling better than 100% cotton.
– Budget-Friendly: Typically more affordable than tri-blends.
– Low Maintenance: Holds its shape well and requires less ironing.
– Good Print Surface: Works well with screen printing and direct-to-garment (DTG) methods.

Cons:
– Less Breathable: Polyester content can trap heat, making it less comfortable in hot weather.
– Slightly Stiffer Feel: Not as soft as 100% cotton or tri-blends initially (though it softens with wear).
– Static and Pilling: May attract lint and develop small fabric balls over time.

Best For: Promotional events, uniforms, workwear, and active environments where durability matters.

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

Pros:
– Ultra-Soft Hand Feel: Feels buttery soft and drapes beautifully—similar to a vintage tee.
– Excellent Drape: Flattering fit that moves with the body.
– Fade Resistant: Retains color vibrancy after multiple washes.
– Moisture Wicking: Polyester helps wick sweat, making it more performance-friendly.

Cons:
– Higher Cost: Usually more expensive than cotton or 50/50 blends.
– Less Durable: More delicate; can snag or wear faster with heavy use.
– Print Limitations: May require special DTG settings; not ideal for plastisol screen printing.

Best For: Fashion-forward apparel, boutique brands, women’s cuts, and soft-style designs with a vintage aesthetic.

How to Choose the Right Fabric

• Prioritize Comfort? → Go for 100% cotton or tri-blends.
• Need Durability on a Budget? → Choose a 50/50 blend.
• Want a Premium, Soft Look? → Tri-blend is ideal.
• Planning Heavy Use or Frequent Washing? → 50/50 or tri-blend offer better longevity.
• Focusing on Sustainability? → 100% organic cotton is the top eco-choice.

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

How to Get the Best Price for Custom T-Shirts (Bulk Quantity Breaks & 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 know how to optimize your order. By leveraging quantity breaks and preparing artwork efficiently, you can significantly reduce your per-unit cost. Here’s how:

Understand Bulk Quantity Breaks

Most screen printing and print-on-demand companies offer tiered pricing based on order volume. The more shirts you order, the lower the price per unit.

• Typical Quantity Tiers:
  Common breaks include 25, 50, 100, 250, and 500 units. For example, 25 shirts might cost $10 each, while 100 shirts drop to $6 each.

• Maximize Your Break Point:
  If you’re close to the next tier (e.g., 90 shirts), consider increasing your order to 100. The small additional cost often results in a much lower price per shirt.

• Group Orders:
  Collaborate with friends, team members, or departments to pool orders and reach higher quantity breaks.

Choose the Right Printing Method

The printing technique affects both cost and quality. Select the method that fits your design and budget.

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

• DTG (Direct-to-Garment):
  Best for complex, full-color designs or small batches. Higher per-unit cost, but no setup fees—ideal if you can’t meet screen printing minimums.

• Heat Transfer or Vinyl:
  Suitable for small runs or specialty fabrics. Less durable over time and not ideal for large orders.

Simplify Your Design to Reduce Costs

Printing costs often depend on design complexity.

• Limit the Number of Colors:
  Each additional color in screen printing requires a separate screen and increases setup time. Stick to 1–3 colors to minimize expenses.

• Minimize Print Area:
  Smaller prints use less ink and labor. Opt for standard placements like left chest or center back.

• Avoid Gradients and Photorealistic Images (for Screen Printing):
  These are better suited to DTG, which is more expensive. Simplify artwork into flat colors when possible.

Prepare Print-Ready Artwork

Well-prepared artwork reduces setup time and avoids costly corrections.

• Use Vector Files (AI, EPS, SVG):
  These scale infinitely without losing quality—essential for clean prints. Avoid low-resolution JPEGs or PNGs.

• Set Correct Dimensions and DPI:
  For DTG or detailed prints, provide high-resolution files (300 DPI at actual print size).

• Outline Fonts and Convert to Paths:
  Prevents font issues during printing. Ensure all text is converted so the printer doesn’t need your font files.

• Include a Mockup:
  Helps the printer understand your vision and reduces back-and-forth communication.

Select Affordable, High-Quality Blank T-Shirts

The blank shirt makes up a big part of the cost.

• Choose Basic, Reliable Brands:
  Gildan, Bella+Canvas, and Hanes offer quality at competitive prices. Premium brands (e.g., American Apparel) cost more.

• Stick to Standard Colors:
  White and black shirts are usually cheaper than specialty colors.

• Consider Fabric Weight and Blend:
  100% cotton is affordable and widely available. Blends (e.g., cotton-polyester) may cost more but offer durability and moisture-wicking.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote.

• Compare at Least 3 Suppliers:
  Use online quote tools from companies like Custom Ink, Printful, Inkthreadable, or local screen printers.

• Ask About Hidden Fees:
  Confirm if setup fees, color charges, or shipping are included.

• Negotiate for Large Orders:
  If ordering 250+ units, ask for a custom discount. Some suppliers offer free setups or reduced rates for repeat customers.

Order Samples First

Always request a physical sample (or “press check”) before full production.

• Verify Print Quality and Fit:
  Avoid costly mistakes in color, sizing, or design alignment.

• Test Durability:
  Wash the sample to ensure the print holds up.

Time Your Order Strategically

• Avoid Rush Fees:
  Place orders well in advance. Rush processing can increase costs by 25–50%.

• Watch for Promotions:
  Many suppliers offer seasonal discounts, first-time customer deals, or free shipping.

By combining smart bulk ordering, efficient artwork, and strategic supplier selection, you can achieve high-quality custom T-shirts at the best possible price. Plan ahead, simplify where you can, and always compare options to maximize your savings.