Seann,
I do 90% plasitsol transfers, and 10% heat transfer vinyl. I have been in business for 4 years, and generate probably $30k in revenue a year. So not big, but not an at home crafter either. I say that for reference only. In terms of suggestions, I have used and had multiple compliments on transfers for the NL 6210. I’m doing a fundraiser campaign for a high school student’s summer mission trip now. She and her friends are in love with that shirt. I have had zero complaints about feel on that shirt from transfers, but what ESPNinc said above is spot on. You have to limit the amount of ink, and that applies to any design. In other words, use distressed as suggested, or use outlines. For example, if you are doing a shirt with a state (I did the state of Texas recently) use an outline of the state, not a filled in image.
Now in terms of other shirts, I will admit, ProworldEd is a genius, and his company is legendary. He has forgotten more about the shirt business than I will ever even learn, but I will politely disagree with one statement he made. I constantly get criticism regarding 6.1 oz gildan like the g200 or g500. The reason they are so widely accepted is because most places are cheap and say, “give me 100 of your cheapest shirts.” You won’t give them a $5.50 next level, when a $1.80 Gildan is available. But here is a compromise if you need a comfortable shirt at a low cost. Try the Gildan g800. It is a 50/50 poly cotton, really soft, and takes transfers well. Cost is only about .10 more than the 5 and 800.
I hope this helps, (and don’t be mad with me proworldEd. ��.) By the way, here is a little plug for them, since I’m going against his advice. Pro World, and PW Customs, may be a little more expensive, but they hands down have the best transfer on the market in my opinion. I have never had to have them reprint, or refund. The only thing ever to happen was that 200 of my 500 transfer order was missing, to which they immediately overnighted the missing ones. Top flight company. Can’t recommend higher.
I currently just do printed heat transfer vinyl, we're waiting on some plastisol transfers from versatranz. I personally HATE how a large vinyl design feels on any garment. Heavy and plasticy yet we have people who absolutely LOVE them. Everyone will have their own preference. I think as long as they can touch and feel the tee before they buy it, it shouldn't be an issue.
