T-shirt weight and fit guide for custom tees
The blank decides how the shirt feels, how it prints and what it costs. Here is how the tees Battle Born Clothing prints for Reno orders compare, in plain terms, so you can pick one before you ask for a quote.
The comparison
| Style | Weight | Fabric | Fit | Inks that work | Best for |
|---|---|---|---|---|---|
| PC61 | 6.1 oz | 100% cotton | Classic, boxy | Plastisol, water-based, discharge, DTF, embroidery | Crews, events, anything that gets worked in; $6.04 blank |
| PC54 | 5.4 oz | 100% cotton | Classic | All | Budget events, giveaways, youth and women's matching |
| PC55 | 5.5 oz | 50/50 blend | Classic | Plastisol, DTF, embroidery | Shift work, summer, low shrink |
| PC450 | 4.5 oz | Ring-spun cotton | Modern | All | Soft team and merch shirts on a budget |
| PC330 | Light | Tri-blend | Modern, drapey | Plastisol, DTF | Premium merch, heathers |
| Comfort Colors 1717 | 6.1 oz | Ring-spun, garment-dyed | Relaxed | Water-based, discharge, plastisol, DTF | Brewery and coffee merch |
| Bella+Canvas 3001 | 4.2 oz | Airlume cotton | Retail, fitted | All | Startups, gyms, retail brands |
| Sport-Tek ST350 | 3.8 oz | 100% polyester | Athletic | Plastisol (poly), DTF | 5Ks, gyms, summer crews |
Weight: what the ounces mean
Ounces are fabric weight per square yard. 6 oz and up is heavyweight: thicker, warmer, more opaque, holds up to abuse. Around 4.2 to 4.5 oz is a retail-weight tee: lighter, softer, drapes more, shows the body more. 5.4 oz is the middle. There is no right answer; a landscaping crew wants the PC61 and a yoga studio wants the Bella 3001.
Fit: classic vs modern vs retail
- Classic (PC61, PC54, PC55): boxier body, roomier through the chest, slightly longer. Runs a bit large. Safe for a mixed group when you do not have everyone's preference.
- Modern (PC450, PC330): a little slimmer and shorter than classic. Still unisex.
- Retail / fitted (Bella 3001): side-seamed, slimmer through the body. Some people size up one.
- Women's cuts (LPC54, LPC450, LST350): shorter body, narrower shoulders, slimmer. Put it on the sign-up form as an option, not a default.
Fabric and ink
100% cotton takes every ink, including water-based and discharge for the soft hand. Blends and tri-blends need plastisol or DTF; discharge needs cotton dye to react with. Polyester needs a low-bleed plastisol or DTF. Garment-dyed cotton like the Comfort Colors 1717 is the best discharge base there is. If you want a specific feel, tell us and we will pick the blank and ink together.
Sizing a mixed order
A rule that works for a general adult crowd when nobody sent sizes: 1 S, 3 M, 4 L, 3 XL, 1 2XL per 12 shirts. For trades crews shift it a size up. For a college group shift it a size down. 2XL and up carry a supplier upcharge of $1-7 per blank by style. Order a 5-10% buffer; a reorder for three shirts costs more per shirt than the buffer did.
Ask which blank fits your order
Questions
Which tee is the best value?
The PC61 at $6.04 blank. Heavy, prints everything, sizes to 6XL, and we consider it quite a bit better than Gildan at the same money.
Which tee is the softest?
The Comfort Colors 1717 (garment-dyed) and the Bella+Canvas 3001 are the softest out of the bag. A discharge print on either has no hand at all.
Do you have youth sizes?
Yes: PC54Y, PC55Y, YST350 and PC78YH among others. Youth apparel has CPSIA labeling rules; we will point you to Battle Born Clothing's guide.