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

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

Choosing the right fabric is crucial when making custom t-shirts—it impacts comfort, durability, print quality, and overall customer satisfaction. Here’s a breakdown of the three most popular fabric options to help you decide which is best for your needs.

100% Cotton

Pros:
– Soft and Breathable: Offers excellent comfort, especially in warmer climates, due to its natural fibers.
– Great for Printing: Absorbs ink well, making it ideal for screen printing, DTG (Direct-to-Garment), and embroidery.
– Eco-Friendly Option: Biodegradable and often available in organic varieties.
– Classic Feel: Provides the traditional t-shirt feel that many customers expect.

Cons:
– Prone to Shrinking: Can shrink significantly after washing if not pre-shrunk.
– Less Durable: May wear out or pill faster than blended fabrics with repeated washing.
– Holds Wrinkles: Wrinkles more easily and may require ironing.

Best For: Everyday wear, promotional shirts, eco-conscious brands, and designs requiring vibrant prints.

50/50 Cotton-Polyester Blend

Pros:
– Balanced Performance: Combines the softness of cotton with the durability and resilience of polyester.
– Reduced Shrinkage: Less likely to shrink compared to 100% cotton.
– Wrinkle and Fade Resistant: Holds its shape and color better over time.
– Affordable: Typically more budget-friendly than tri-blends.

Cons:
– Less Breathable: Polyester content reduces breathability, making it less ideal for hot weather.
– Prone to Pilling: May develop small fabric balls (pills) with frequent wear and washing.
– Not as Soft: Can feel slightly stiffer than 100% cotton or tri-blends.

Best For: Active wear, workwear, budget-conscious orders, and environments where durability is key.

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

Pros:
– Ultra-Soft Feel: Known for a luxurious, lightweight, and smooth texture—often compared to a vintage or heathered look.
– Excellent Drape: Flatters the body with a slightly more fitted, flowing silhouette.
– Fade Resistant: Retains print color well and resists fading over time.
– Minimal Shrinkage: Very stable after washing.

Cons:
– Higher Cost: More expensive than cotton or 50/50 blends.
– Lower Absorbency: Not ideal for heavy sweating due to lower moisture absorption.
– Sensitive to Heat: Can be damaged by high heat during printing or washing if not handled properly.

Best For: Fashion-forward apparel, boutique brands, premium gifts, and soft, vintage-style designs.

Choosing the Right Fabric

• Prioritize Comfort & Sustainability? Go with 100% Cotton.
• Need Durability on a Budget? Choose the 50/50 Blend.
• Want Premium Softness & Style? Opt for Tri-Blend.

Consider your audience, use case, care instructions, and design technique when making your final decision. Each fabric has its strengths—select the one that aligns best with your brand and customer expectations.

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, support an event, or outfit a team—especially when you leverage quantity breaks and optimize your design process. Here’s how to get the best price without sacrificing quality.

1. Understand Bulk Quantity Breaks

Most screen printing and embroidery companies offer tiered pricing, where the price per shirt drops as your order size increases. For example:

• 1–24 shirts: $12 each
• 25–49 shirts: $9 each
• 50–99 shirts: $7 each
• 100+ shirts: $5 each

Tips to Maximize Savings:

• Order at the threshold of the next tier (e.g., order 50 instead of 40) to get a significantly lower per-unit cost.
• Combine orders with others—if you’re part of a group or organization, pool orders to reach higher quantity breaks.
• Consider future needs—if you anticipate needing more shirts later, order extra now to lock in lower prices.

2. Choose the Right Supplier

Not all print shops offer the same pricing or quality. Compare:

• Online vs. local printers: Online services (like Printful, Custom Ink, or RushOrderTees) often have competitive bulk rates and volume discounts. Local shops may offer faster turnaround and better personal service.
• Minimum order requirements: Some suppliers waive minimums but charge more per unit. Others offer deeper discounts at 100+ pieces.
• Shipping costs: Bulk orders can have high shipping fees—factor this into your total cost or look for free shipping promotions.

3. Optimize Your Artwork for Lower Printing Costs

Design choices directly impact price. Follow these artwork tips to reduce production costs:

• Limit the number of print colors: Each additional color increases setup time and cost. Stick to 1–3 colors for screen printing.
• Use vector files (AI, EPS, PDF): High-resolution vector artwork ensures crisp prints and avoids extra fees for file cleanup.
• Simplify your design: Complex designs with gradients or fine details may require more expensive printing methods (like DTG). Simpler = cheaper.
• Avoid all-over prints: Full-shirt designs cost more. Focus on chest prints, back logos, or sleeve details.

4. Select Cost-Effective Shirt Styles

Basic styles (like Gildan 5000 or Bella+Canvas 3001) are cheaper than premium or fashion-fit shirts. Consider:

• Cotton vs. blends: 100% cotton is usually the most affordable and easiest to print on.
• Color of the shirt: White and light-colored shirts are cheapest to print on. Dark shirts require an underbase (white ink), increasing cost.

5. Plan Ahead and Order Early

Rush orders often come with a 25–50% markup. To get the best price:

• Place orders 2–3 weeks in advance to avoid rush fees.
• Take advantage of seasonal promotions—many printers offer discounts during back-to-school, holidays, or slow business periods.

6. Request Samples and Quotes

Before committing to a bulk order:

• Order a sample to check print quality and shirt feel.
• Get multiple quotes from different suppliers—don’t assume the first quote is the best.

By combining smart ordering strategies with print-friendly artwork, you can significantly reduce your custom t-shirt costs while still achieving a professional, high-quality result.