Comparison of Custom T-Shirt Printing Methods for Walmart

Choosing the Right Fabric for Your Walmart Custom T-Shirts: 100% Cotton vs. 50/50 Blend vs. Tri-Blend

When creating custom t-shirts through Walmart’s print-on-demand service, one of the most important decisions you’ll make is selecting the fabric. The material affects comfort, durability, print quality, and how the shirt feels over time. Here’s a breakdown of the three most common fabric options: 100% Cotton, 50/50 Blend, and Tri-Blend.

100% Cotton

Pros:
– Soft and Breathable: Offers a classic, natural feel that’s ideal for everyday wear, especially in warmer weather.
– Eco-Friendly Option: Made entirely from natural fibers, making it biodegradable and often preferred by environmentally conscious buyers.
– Great for Printing: Absorbs ink well, resulting in vibrant and crisp print designs, especially with screen printing or direct-to-garment (DTG) methods.
– Comfortable Against Skin: Hypoallergenic and gentle, making it suitable for sensitive skin.

Cons:
– Prone to Shrinking: May shrink after washing, especially if not pre-shrunk.
– Less Durable Over Time: Can wear out faster than blended fabrics and is more susceptible to pilling and stretching.
– Wrinkles Easily: Requires ironing for a crisp look.

Best For: Casual wear, summer styles, eco-minded customers, and designs with bold, detailed artwork.

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

Pros:
– Durable and Long-Lasting: The polyester adds strength, helping the shirt resist shrinking, fading, and wear from repeated washing.
– Wrinkle-Resistant: Holds its shape better and requires less ironing.
– Affordable: Often priced lower than tri-blends, making it a cost-effective option for bulk orders.
– Lightweight: Offers a good balance between softness and structure.

Cons:
– Less Breathable: Polyester traps heat more than cotton, which may make it less comfortable in hot weather.
– Slight Sheen: The polyester content can give the fabric a slightly synthetic look.
– Not as Soft Initially: May feel stiffer than 100% cotton or tri-blends when new (though it softens over time).

Best For: Workwear, promotional shirts, school events, and situations where durability and cost are top priorities.

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

Pros:
– Ultra-Soft and Silky Feel: Known for its luxurious, vintage-inspired texture that feels broken-in from day one.
– Excellent Drape: Flatters the body with a slightly more fitted, flowing silhouette.
– Color Retention: The polyester helps maintain print vibrancy, while rayon adds depth and richness to colors.
– Resists Shrinkage: More stable than 100% cotton due to synthetic fibers.

Cons:
– Higher Price Point: Usually the most expensive option due to materials and manufacturing.
– Less Durable Under Stress: While soft, the fabric can be more prone to snagging or pilling with heavy use.
– May Fade Over Time: Rayon can degrade slightly with repeated washing, especially in high-heat settings.

Best For: Fashion-forward designs, gift items, boutique-style apparel, and customers seeking a premium, soft hand-feel.

Final Tips for Choosing

• Consider the Purpose: Is the shirt for daily wear, an event, or a keepsake? Match the fabric to the use case.
• Think About Climate: Cotton breathes well in heat; blends offer more versatility in varying temperatures.
• Evaluate Print Design: Bold graphics work well on cotton and 50/50 blends, while tri-blends enhance softer, vintage-style prints.
• Know Your Audience: Comfort seekers may prefer tri-blends, while budget-focused buyers might lean toward 50/50 blends.

By understanding the differences between 100% cotton, 50/50 blends, and tri-blends, you can confidently select the ideal fabric for your Walmart custom t-shirts—balancing comfort, durability, appearance, and cost.

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

Ordering custom t-shirts in bulk from Walmart can be a cost-effective way to outfit your team, event, or organization—but getting the best deal requires strategy. Here’s how to maximize savings through bulk pricing and ensure your design looks great without costly mistakes.

Understand Walmart’s Bulk Quantity Breaks

Walmart’s custom t-shirt pricing (typically available through Walmart.com’s partner services like CustomInk or third-party vendors on the platform) uses tiered pricing based on order volume. The more you order, the lower the per-unit cost.

• Start with 24+ shirts: Most vendors offer their first discount tier at 24 units. This is ideal for small groups.
• Aim for 48+ shirts: Moving into the 48–71 range often unlocks better per-shirt pricing.
• Maximize at 72+ shirts: Orders of 72 or more usually get the steepest discounts—sometimes 20–30% off smaller quantities.
• Consider 144+ for major savings: For large events or organizations, ordering in gross quantities (144+) can significantly reduce costs.

Pro Tip: Place a test order (1–2 shirts) first to check print quality and sizing before going bulk.

Choose the Right Shirt Style and Color

Not all shirts are priced the same. To keep costs low:

• Opt for basic styles: 100% cotton or cotton/poly blends (like Gildan or Hanes) are cheaper than performance or organic fabrics.
• Stick to standard colors: White, black, and navy are typically the most affordable. Specialty colors or heathered fabrics may cost extra.
• Use the same style across orders: Mixing styles increases setup fees and reduces bulk discount eligibility.

Simplify Your Design for Lower Printing Costs

Printing is where costs can add up quickly. Keep your artwork simple and print-friendly:

• Limit the number of print locations: Each print area (front, back, sleeve) incurs a separate fee. A single front print is cheapest.
• Use fewer colors: Most vendors charge per ink color. Stick to 1–3 colors to avoid high screen setup fees.
• Avoid gradients and photo-realistic images: These often require expensive digital printing. Opt for bold, flat-color designs.

Prepare Print-Ready Artwork

Submitting high-quality artwork prevents delays and extra charges:

• Use vector files (AI, EPS, SVG): These scale perfectly and are preferred by printers.
• Submit high-res raster files (300 DPI): If using PNG or JPG, ensure they’re at least 300 DPI and sized to print dimensions.
• Outline all fonts: Prevent font issues by converting text to outlines.
• Stick to standard color modes: Use Pantone (PMS) or CMYK for screen printing; RGB can cause color shifts.
• Leave safe margins: Keep critical design elements at least 1″ from seams and edges.

Pro Tip: Use free tools like Canva or Inkscape to design, or hire a designer on Fiverr for under $50.

Time Your Order Strategically

• Order early: Rush processing and shipping fees can add 20–50% to your total. Plan at least 2–3 weeks ahead.
• Watch for seasonal promotions: Back-to-school, holidays, and end-of-season sales may include discounts on apparel or free setup fees.
• Compare vendors: Walmart partners with multiple print providers. Check each for bundled deals, promo codes, or waived fees.

Order Samples and Confirm Details

Before finalizing a large order:

• Request a physical proof: Some vendors offer printed proofs for $10–$20—worth it to avoid costly errors.
• Confirm shirt sizes early: Use Walmart’s size charts and order a size pack if needed. Free exchanges may be available for incorrect sizes.
• Double-check your order: Verify quantities, colors, and artwork placement before checkout.

By leveraging bulk quantity breaks, simplifying your design, and preparing print-ready artwork, you can get high-quality custom t-shirts from Walmart at the lowest possible price. Plan ahead, compare options, and always test first!