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

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

When customizing t-shirts for your brand, event, or personal use, the fabric you choose plays a crucial role in comfort, durability, appearance, and print quality. Three of the most popular fabric options are 100% cotton, 50/50 cotton-polyester blends, and tri-blends. Here’s a breakdown to help you decide which is best for your needs.

100% Cotton

Pros:
– Soft and Breathable: Offers a natural, soft feel that’s ideal for sensitive skin and warm weather.
– Eco-Friendly: Biodegradable and often available in organic options.
– Great for Printing: Absorbs ink well, making it excellent for screen printing and vibrant designs.
– Classic Feel: Preferred by many for its traditional t-shirt texture and drape.

Cons:
– Prone to Shrinkage: Can shrink significantly after washing, especially if not pre-shrunk.
– Less Durable: More susceptible to wear, pilling, and fading over time.
– Wrinkles Easily: Requires ironing to maintain a crisp appearance.
– Holds Moisture: Not ideal for athletic wear, as it retains sweat.

Best For: Everyday wear, promotional shirts, eco-conscious brands, and screen-printed designs where a classic look is desired.

50/50 Cotton-Polyester Blend

Pros:
– Durable & Resilient: Polyester adds strength, reducing pilling and extending shirt life.
– Minimal Shrinkage: Holds its shape better after repeated washes.
– Wrinkle-Resistant: Maintains a neat appearance with less ironing.
– Affordable: Often priced lower than 100% cotton or tri-blends.
– Moisture-Wicking: Dries faster than pure cotton.

Cons:
– Less Breathable: Can feel warmer due to reduced airflow.
– Slightly Stiffer Feel: May not have the ultra-soft hand of 100% cotton.
– Printing Challenges: Requires specific inks (like plastisol) for best results; can be prone to “fuzzing” with certain print methods.

Best For: Workwear, events, fundraisers, and situations where durability and cost-efficiency are priorities.

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

Pros:
– Ultra-Soft & Lightweight: Feels buttery smooth with a luxurious drape.
– Excellent Drape & Fit: Conforms well to the body, giving a more fitted, modern look.
– Resists Wrinkles & Shrinkage: Holds shape and appearance after washing.
– Vintage Aesthetic: Often used for a heathered, retro look that ages well.
– Good for DTG Printing: Works beautifully with direct-to-garment printing for detailed, soft-hand designs.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Less Durable for Heavy Use: Softer fibers can be more prone to snagging.
– Not Ideal for Heavy Ink Prints: May not support thick plastisol inks as well.

Best For: Fashion-forward apparel, boutique brands, retail sales, and designs using DTG printing with soft, vintage-inspired aesthetics.

Final Tips for Choosing

• Consider the Use: Is it for daily wear, sports, or special events?
• Think About Print Method: Screen printing works well on cotton and 50/50s; DTG shines on tri-blends.
• Prioritize Comfort vs. Durability: Softness favors cotton and tri-blends; longevity favors 50/50s.
• Factor in Budget: 50/50 blends offer great value, while tri-blends are premium.

By understanding the strengths and trade-offs of each fabric, you can select the perfect t-shirt material that aligns with your customization goals and audience expectations.

How to Get the Best Price on Custom T-Shirts (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 know how to optimize pricing and design. Here’s how to get the best value without sacrificing quality.

Leverage Bulk Quantity Breaks

Most printers offer tiered pricing based on order size, meaning the more you order, the less you pay per shirt. To maximize savings:

• Order in standard volume tiers: Common breaks are 25, 50, 100, 250, and 500 units. Jumping from 90 to 100 shirts often results in a significant per-unit discount.
• Consolidate orders: Instead of placing multiple small orders, combine needs over several months into one large order.
• Mix sizes, same design: Bulk discounts typically apply to total quantity, not per size. You can mix S–XXL as long as the design and shirt style remain consistent.
• Choose basic colors and styles: Premium or fashion-fit shirts and specialty colors (like neon or heather grey) may cost more. Stick to classic colors (white, black, navy) for the lowest pricing.
• Compare vendors: Use online quote tools from multiple suppliers (e.g., Printful, Custom Ink, RushOrderTees, local screen printers) to find the best per-unit rates at your volume.

Optimize Your Artwork to Reduce Costs

The complexity of your design directly impacts pricing—especially with screen printing. Follow these tips to keep costs low:

• Limit the number of colors: Each ink color requires a separate screen and setup fee. Stick to 1–3 colors to minimize charges.
• Use vector artwork: Provide logos or graphics in vector format (AI, EPS, SVG) so they can be resized without quality loss. This avoids costly recreation fees.
• Simplify your design: Avoid gradients, fine details, or photorealistic images. Bold, solid shapes and clean lines are easier and cheaper to print.
• Choose suitable print locations: Printing on just the front is cheaper than front + back or sleeves. Each additional location increases setup and printing time.
• Confirm file specs early: Supply high-resolution (300 DPI), properly sized artwork with outlined fonts to prevent delays or rework fees.

By combining smart bulk ordering with print-friendly artwork, you can significantly reduce your per-shirt cost while still achieving a professional result. Always request a physical or digital proof before full production to ensure quality and avoid costly mistakes.