If you're looking to start a custom apparel or merchandise business, choosing the right printing method can make a huge difference. From classic screen printing to cutting-edge
Direct-to-Film (DTF) technology, each method has its pros, cons, and ideal use cases. In this guide, we'll compare DTF printing with other common methods—screen printing, dye sublimation, DTG (Direct-to-Garment), and vinyl heat transfer—to help you understand their differences.
We'll break down how each technique works, their cost factors, scalability, durability, and typical product outcomes, all in an easy-to-read way. Whether you're a beginner or an experienced entrepreneur looking to expand your print-on-demand offerings, this comparison will give you real-world insights to make an informed decision.
Printing methods aren't one-size-fits-all. For example, the method that's best for 500 identical T-shirts might not be cost-effective for a single personalized hoodie. Likewise, a technique that produces vibrant, full-color images on a cotton tee might not work at all on a polyester jersey or a ceramic mug. By understanding the strengths and weaknesses of each printing approach, you can choose the method (or combination of methods) that fits your business model. Let's dive into each printing technique and see how they stack up against each other, especially against the rising star, DTF printing.
Screen Printing
Screen printing (or silk screening) is one of the oldest and most popular methods for printing on apparel. It involves pushing ink through a mesh stencil (screen) onto the fabric. Each color in the design is applied with a separate screen, so multi-color designs require multiple screens and more setup time. Screen printing has been used for decades and remains a go-to for businesses needing bulk orders like team uniforms, corporate event tees, or any situation where you need hundreds or thousands of identical prints.
Pros:
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Highly Efficient for Large Orders: Once set up, screen printing is extremely fast and cost-effective for high volumes. The cost per shirt drops dramatically for big runs, making it economical for bulk orders.
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Durable, Long-Lasting Prints: Screen print inks create vibrant and durable designs that withstand many washes without significant fading. Prints can often last as long as the garment itself.
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Versatile on Materials: This method works on a wide range of fabrics, including cotton, polyester, and blends, and other items like tote bags and caps.
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Great Color Coverage: Because ink is applied in thick layers, colors can be very bold and opaque. This is excellent for printing solid shapes or logos, especially on dark garments.
Cons:
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Time-Consuming Setup: Significant prep work is required before printing the first item. Screens must be created and aligned for each color. This makes small orders labor-intensive and relatively expensive per piece.
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Limited Colors & Complexity: Screen printing is generally best for designs with a few solid colors. Highly detailed or photorealistic designs are challenging to reproduce with screens.
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Not Ideal for On-Demand Personalization: Due to the setup involved, screen printing isn't practical for one-off personalized items or print-on-demand models where each order is a different design.
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Space and Equipment Needs: Running a screen printing operation requires dedicated equipment (screens, press, conveyor dryer) and a dedicated workspace. The cleanup of inks and screens can also be messy.
Real-world example: If a local brewery needs 300 promotional T-shirts for a festival, screen printing is the fastest and cheapest way to produce them. The print shop can set up one or two screens and rapidly print all 300 with consistent quality. However, if that same brewery wanted 300 shirts each with a different design, screen printing would struggle—that's when you'd look at digital methods like DTG or DTF.
Direct-to-Garment (DTG) Printing
Direct-to-Garment printing is a modern digital method where a specialized inkjet printer applies ink directly onto the fabric, much like printing on paper. The garment is first pre-treated to help the ink bond to the fibers, then the design is sprayed onto the fabric and heat-cured. DTG has become very popular with print-on-demand services and small businesses because it requires no screen setup—you can print one-offs or short runs easily by just loading the design file.
Pros:
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Excellent for Detailed, Full-Color Designs: DTG can produce photorealistic prints with tons of detail and color gradations. Because it's a digital process, it handles intricate artwork or designs with dozens of colors just as easily as a simple design.
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No Minimums – Great for Small Batches: With virtually no setup per design, you can economically print one shirt at a time. This on-demand capability is why DTG is a favorite for online stores and dropshippers.
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Soft Feel on Fabric: DTG uses water-based inks that soak into the garment's fibers, resulting in a print that is usually quite soft to the touch. Many customers appreciate that a DTG print doesn't have that "plastic" feel.
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Versatile and Easy to Use: From a user standpoint, DTG printing can be simpler than screen printing. Load the shirt, hit print, and the machine does the work.
Cons:
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Slower for Large Orders: DTG prints one garment at a time, and each can take a few minutes or more. For a large order (hundreds of shirts), DTG will be much slower and often more costly per shirt than methods like screen printing.
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Best on Cotton (Material Limitations): DTG ink bonds best with high-cotton content fabrics. While it works on cotton/poly blends, you might see duller colors or lower wash durability outside of high-cotton materials.
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Requires Pre-Treatment and Maintenance: For dark garments, you must pre-treat the fabric so the white ink adheres and colors pop. DTG printers also require regular maintenance—print heads can clog if not used frequently.
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Print Durability is Decent but Not the Best: DTG prints are usually quite durable, but they can be less wash-resistant than screen prints or sublimation. Over time, you might see some fading or cracking.
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Higher Cost per Print for Large Runs: The ink for DTG is relatively expensive, and the cost per print remains roughly the same whether you print 1 or 100. This means DTG's cost advantages flip when it comes to bulk orders.
Real-world example: If you run an online store selling custom graphic tees with 50 different designs, DTG is ideal. You can print each single shirt as the order comes in. However, if a local school asks you to print 200 identical shirts for a fundraiser, DTG will be time-consuming and likely too expensive. DTG is also not ideal for sportswear like polyester jerseys—sublimation or DTF might handle that better.
