Comparison of Custom T-Shirt Printing Methods

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

Choosing the right fabric is crucial when ordering custom t-shirts. It affects comfort, durability, print quality, and how your design looks and feels. Here’s a breakdown of the three most popular options—100% Cotton, 50/50 Blend, and Tri-blend—to help you make the best decision.

100% Cotton

Pros:
– Soft and breathable, ideal for everyday wear
– Absorbs ink well, resulting in vibrant, crisp prints
– Natural feel against the skin, great for sensitive skin
– Biodegradable and eco-friendly

Cons:
– More prone to shrinking (especially if not pre-shrunk)
– Can wrinkle easily
– Less durable over time—may thin or pill with frequent washing

Best For:
Casual wear, promotional giveaways, events in warm weather, or when a classic, natural cotton feel is desired.

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

Pros:
– Combines softness of cotton with durability and stretch of polyester
– Resists shrinking and wrinkling better than 100% cotton
– Holds its shape well after multiple washes
– Slightly more affordable than premium cotton or tri-blends

Cons:
– Less breathable than 100% cotton, may feel warmer
– Print colors can appear slightly less vibrant due to polyester content
– Can develop pilling over time with heavy use

Best For:
Workwear, school events, or when durability and cost-effectiveness are priorities.

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

Pros:
– Ultra-soft, smooth texture with a slight drape (similar to a vintage tee)
– Excellent print clarity and soft-hand feel for designs
– Resists shrinking and fading better than 100% cotton
– Lightweight and breathable, yet durable

Cons:
– More expensive than cotton or 50/50 options
– Slightly less absorbent than 100% cotton
– May require more delicate washing to maintain softness

Best For:
Fashion-forward apparel, boutique brands, or premium custom tees where comfort and a modern look are key.

Final Tips for Choosing

• Consider the Use: Will the shirts be worn daily, for events, or as merchandise?
• Think About Climate: Cotton breathes best in heat; blends offer better moisture-wicking.
• Design Complexity: Tri-blends and cotton offer the best print quality for detailed artwork.
• Budget: 50/50 blends often provide the best balance of price and performance.

By understanding the strengths and trade-offs of each fabric, you can select the ideal material that aligns with your brand, audience, and goals for your custom t-shirts.

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

Ordering custom t-shirts in bulk can be a cost-effective way to promote your brand, outfit a team, or sell merchandise. To maximize your savings and ensure top-quality results, follow these key strategies focused on bulk pricing and artwork preparation.

Leverage Bulk Quantity Breaks for Lower Per-Unit Costs

One of the most effective ways to reduce the cost per shirt is by taking full advantage of bulk quantity breaks offered by most print providers.

• Order in Larger Quantities: Most suppliers offer tiered pricing—typically at 12, 24, 50, 100, 250, and 500+ units. The more you order, the lower your per-unit cost. For example, ordering 250 shirts instead of 100 could reduce the price per shirt by 20–40%.

• Consolidate Designs When Possible: If you’re ordering multiple designs, try to standardize shirt styles, colors, and sizes across designs. This reduces setup fees and can qualify your total order for higher quantity breaks.

• Group Orders with Others: Partner with teams, clubs, or event groups to combine orders and reach higher quantity tiers. This collaborative approach spreads savings across multiple parties.

• Compare Suppliers’ Break Points: Not all companies offer the same bulk discounts. Use online quote tools to compare pricing across vendors at various quantities (e.g., 50 vs. 100 vs. 250) to identify the most cost-effective option.

Optimize Your Artwork to Reduce Printing Costs

High-quality, print-ready artwork isn’t just about aesthetics—it directly impacts production efficiency and pricing.

• Use Vector Files (AI, EPS, SVG): Vector graphics scale infinitely without losing quality and are preferred by screen printers and DTG (direct-to-garment) services. They reduce setup time and errors, potentially lowering costs.

• Simplify Your Design: Fewer colors mean lower screen printing setup fees. A one- or two-color design is significantly cheaper than a full-color design. Consider design elements that use fabric color as a “color” to reduce ink usage.

• Provide High-Resolution Raster Files (300 DPI): If using PNG or JPG, ensure your image is at least 300 DPI at the intended print size (e.g., 10” wide = 3000 pixels). Blurry or pixelated artwork may require costly redesigns.

• Follow the Printer’s Template: Use the supplier’s size and bleed guides to position your design correctly. Properly formatted artwork avoids delays and additional correction fees.

• Limit Print Locations: Printing on one location (e.g., front chest) is cheaper than multiple locations (front and back). Each additional print area increases labor and setup costs.

By strategically increasing your order size and preparing professional, simplified artwork, you can significantly reduce the total cost of your custom t-shirts—without sacrificing quality. Always request a physical sample or digital proof before finalizing your bulk order to ensure satisfaction.