Comparison of Custom T-Shirt Printing Methods

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

When designing custom t-shirts for your website, one of the most important decisions you’ll make is selecting the fabric. The material impacts comfort, durability, print quality, and overall customer satisfaction. Here’s a breakdown of the three most popular fabric options to help you guide your customers and optimize your offerings.

100% Cotton

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear.
– Naturally comfortable: Feels great against the skin, especially in ring-spun varieties.
– Excellent printability: Holds vibrant screen prints and direct-to-garment (DTG) designs well.
– Eco-friendly appeal: Biodegradable and preferred by environmentally conscious buyers.

Cons:
– Prone to shrinking: Especially if not pre-shrunk; may shrink 3–5% after washing.
– Less durable over time: Can wear out faster with frequent washing and wear.
– Wrinkles easily: Requires ironing for a crisp look.

Best For: Customers who value softness, breathability, and a classic cotton feel—ideal for casual tees, promotional giveaways, and eco-focused brands.

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

Pros:
– Durability: Polyester adds strength, reducing pilling and extending the shirt’s life.
– Reduced shrinkage: Holds its shape better over time compared to 100% cotton.
– Affordable: Often priced lower than tri-blends, offering good value.
– Lightweight and soft: More breathable than 100% polyester while still feeling soft.

Cons:
– Less breathable: Polyester traps heat, making it less ideal for hot climates.
– Can feel slightly synthetic: Some customers may notice a less “natural” texture.
– Print details may blur: DTG prints might appear slightly softer than on cotton.

Best For: Budget-conscious customers, event staff shirts, or high-use apparel where durability matters more than ultra-softness.

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

Pros:
– Ultra-soft, vintage feel: Offers a buttery-soft texture with a slightly worn-in look.
– Excellent drape: Flatters the body and moves naturally with the wearer.
– Resists shrinking and fading: Holds shape and color well over time.
– Breathable and moisture-wicking: Comfortable for layering or light activity.

Cons:
– Higher price point: More expensive due to blend complexity and fabric quality.
– Less sturdy for heavy use: May not withstand rough wear as well as cotton or 50/50 blends.
– Care required: Often needs gentle washing to maintain softness and prevent pilling.

Best For: Premium custom tees, fashion-forward designs, boutique brands, and customers seeking a luxurious, soft hand-feel.

Final Tips for Your Website

• Show fabric comparisons: Use side-by-side photos or swatches to help customers visualize differences.
• Highlight care instructions: Educate buyers on how to maintain each fabric type.
• Offer multiple options: Cater to different preferences and budgets by providing all three fabric types.
• Use descriptive language: Words like “ultra-soft,” “lightweight,” or “vintage feel” help set expectations.

By understanding the strengths of 100% cotton, 50/50 blends, and tri-blends, you can guide customers toward the perfect custom t-shirt—boosting satisfaction and repeat business.

How to Get the Best Price for Websites to Make Custom T-Shirts (Bulk Quantity Breaks, Artwork Tips)

Understand Bulk Quantity Breaks

When ordering custom t-shirts in bulk, one of the best ways to reduce your cost per unit is by leveraging quantity breaks. Most online printing platforms offer tiered pricing, meaning the more shirts you order, the cheaper each one becomes.

• Start with larger quantities: Ordering 100+ shirts typically reduces the per-unit cost significantly compared to smaller batches like 25 or 50.
• Compare price tiers: Check how prices drop at thresholds like 50, 100, 250, and 500 units across different websites (e.g., Printful, Custom Ink, Gooten, or RushOrderTees).
• Avoid mixing too many designs or colors: Each unique design or color variation may reset the bulk discount. Stick to one or two designs across different sizes and colors to maximize savings.

Choose the Right Website for Volume Pricing

Not all custom t-shirt websites offer the same bulk pricing models. Consider these top platforms known for competitive bulk rates:

• Custom Ink: Offers transparent bulk pricing with frequent sales and promo codes. Great for nonprofits and large groups.
• RushOrderTees: Specializes in bulk orders with deep discounts at higher volumes and fast turnaround.
• Printify / Printful: Ideal if you’re selling rather than just ordering; integrates with Shopify and offers competitive per-item rates at scale.
• T Shirt Elephant: Known for high-quality blanks and good pricing on orders over 100 units.

Always request a quote for large orders — some sites offer custom pricing for very large quantities (500+).

Optimize Your Artwork to Reduce Costs

The design you submit can directly affect your final price, especially with printing methods like screen printing or DTG (direct-to-garment).

Simplify Your Design

• Limit the number of colors: Screen printing charges extra per color. Designs with 1–3 colors are much cheaper than full-color prints.
• Use vector files (AI, EPS, SVG): These scale cleanly and are preferred by printers, reducing setup errors and revision fees.
• Follow print area guidelines: Avoid printing too close to seams or edges — this can increase waste and printing complexity.

Prepare Files Correctly

• Use high-resolution images (300 DPI minimum) for DTG printing to prevent blurry results.
• Outline fonts in vector software to avoid typeface licensing issues.
• Submit color-separated files if required — this speeds up production and may reduce setup fees.

Time Your Order Strategically

• Look for seasonal sales: Many sites offer discounts around back-to-school, holidays, or end-of-year clearance.
• Avoid rush processing: Expedited production and shipping add significant costs. Plan ahead to use standard turnaround times.
• Join loyalty programs or email lists: Sites like Custom Ink or RushOrderTees often send exclusive bulk-order coupons to subscribers.

Request Samples Before Bulk Ordering

Always order a sample or test print before committing to a large run. This ensures:
– Color accuracy
– Proper sizing and fit
– Print quality meets expectations

Many sites offer low-cost or free samples — use them to avoid costly mistakes.

Negotiate for Very Large Orders

For orders over 500 units:
– Contact sales representatives directly — many sites offer unadvertised discounts for large-volume customers.
– Ask about blank shirt discounts if you’re open to standard colors or brands.
– Inquire about free setup fees or waived art charges for bulk orders.

Final Tips for Maximum Savings

• Bundle styles wisely: Mixing men’s, women’s, and youth cuts is fine, but keep printing locations (front, back, sleeve) consistent to avoid setup fees.
• Choose standard colors: White, black, and navy usually cost less than specialty colors.
• Use one printing location: Front-only prints are cheaper than multi-location designs.

By combining smart bulk ordering, optimized artwork, and strategic timing, you can significantly reduce the cost per shirt and get the best value from custom t-shirt websites.