The excitement of creating custom t-shirt designs can quickly shift to addressing technical decisions, with one of the most critical being the choice of an apparel printing method.
Among the various custom printing options, direct-to-garment (DTG) printing and screen printing stand out as the most popular methods and for this, most turn to ApparelGraphics.com. Selecting the right technique is essential for ensuring high-quality results, managing costs effectively, and building a scalable business foundation.
Key factors to consider when comparing these printing methods include:
- Compatibility with the design
- Cost-effectiveness
- Sustainability
This guide explores the distinctions between DTG and screen printing, highlights the types of designs each method is best suited for, and evaluates their sustainability.
What is DTG Printing?
Direct-to-garment printing, commonly referred to as DTG printing, is a technique where ink is applied directly to the garment after it has been pre-treated with a bonding agent. The ink penetrates the garment’s fibers, locking into place through the bond created by the pre-treatment. This process ensures the ink adheres to the fabric, producing vibrant and durable prints. The method is similar to printing on paper, but instead of paper, the surface is a fabric garment.
After the design is printed, the garment is carefully removed from the printer and placed onto a conveyor dryer. The dryer evaporates the pre-treatment and cures the ink, creating a smooth, lasting print that feels natural to the touch.
DTG printing is especially suited for creating intricate and photorealistic designs, such as those with gradients or a wide range of colors. Its digital nature eliminates the need for complex setup processes, making it an excellent choice for small runs or custom orders. When partnered with a print-on-demand provider, DTG printing allows businesses to minimize upfront costs, as products are only printed when a customer places an order.
What is Screen Printing?
Screen printing is a traditional and widely used printing method that involves pressing ink through a mesh stencil (or screen) directly onto fabric. Each color in the design requires its own screen, meaning that multicolored designs necessitate multiple screens. The ink layer applied during screen printing is often thicker than with DTG printing, resulting in prints with a bold, textured feel that is both durable and visually striking.
The setup process for screen printing is more time-intensive than DTG, as each color requires a separate stencil. Preparing the screens involves creating a template for each color in the design, aligning them precisely to ensure the final image appears as intended. Once the screens are prepared, however, the actual printing process is efficient and well-suited for producing large quantities of garments.
Screen printing is highly cost-effective for bulk orders, making it a popular choice for projects like team uniforms, event merchandise, and large-scale promotional apparel. Its ability to create vibrant prints with thick ink application ensures a professional look that holds up well over time.
DTG vs. Screen Printing: The Differences
When choosing between DTG and screen printing, several factors must be considered, such as print quality, design complexity, and the ability to handle different production volumes. Let’s explore how these two printing methods compare.
Print Quality and Durability
DTG prints are known for their exceptional clarity and fine details, making them ideal for complex designs that include multiple colors or gradients. The ink bonds directly with the fabric, creating a soft, smooth feel while ensuring the print remains vibrant and durable even after multiple washes.
On the other hand, screen printing is renowned for its durability due to the thicker layers of ink applied during the printing process. This thicker ink layer makes screen-printed garments particularly resistant to wear and tear, frequent washing, and heavy use, which makes it a great choice for workwear, uniforms, and other merchandise that needs to endure long-term use.
Print Complexity
DTG printing excels at handling intricate and detailed designs. Unlike screen printing, where each color requires a separate screen to be set up, DTG printers can produce the entire design at once, regardless of how complex it is.
With DTG printing, design complexity does not impact the product cost, which makes it a preferred method for businesses that offer a wide range of designs, including those with intricate details or high color diversity.
In contrast, screen printing is most effective for simpler designs with solid graphics and fewer details. This includes basic typography, geometric shapes, symbols, and minimalistic designs. The process of creating stencils for intricate designs in screen printing is time-consuming, and achieving precision with small details can be challenging.
Screen printing is typically better suited for designs with fewer colors, as each color requires its own screen. Print providers often limit the number of colors that can be used in a design, with most allowing up to 9 colors. Additionally, the cost of screen printing generally increases with the number of colors in the design.
Color Vibrancy
Both DTG and screen printing produce vibrant prints, but they achieve it in different ways. In screen printing, the ink is applied in thick layers, which can make designs pop, especially on darker fabrics. This method is particularly effective for designs that use only a few colors or those that rely on high contrast.
DTG printing also offers excellent color vibrancy, with the ability to apply a wide range of colors. The ink is absorbed directly into the fabric, creating smooth, natural-looking prints. This is especially beneficial for photorealistic or highly detailed designs, where color accuracy is paramount.
Fabric Suitability
DTG printing works best on 100% cotton fabrics or cotton blends, as the ink absorbs well into these materials, creating a soft, natural feel. DTG prints are suitable for both light and dark fabrics, thanks to a pre-treatment process used on darker garments. This pre-treatment creates a white underbase that ensures the colors appear vivid on dark fabrics.
Screen printing, however, is more versatile when it comes to fabric types. It can be used on a wide variety of materials, including polyester, nylon, and other synthetic blends, which makes it ideal for athletic wear or performance fabrics. Screen printing can also be applied to both light and dark fabrics without the need for pre-treatment, as the thicker ink layers provide high opacity, even on dark textiles.
However, screen printing requires specific inks for different fabric types, which can result in variations in how the same design looks on different materials. DTG printing, on the other hand, produces consistent results, regardless of the fabric.
Sustainability
Compared to traditional screen printing, DTG printing has a lower environmental impact, as it helps to reduce overproduction and minimizes textile waste by only printing on demand. There are no minimum order requirements, which makes it more sustainable, especially for smaller businesses or those with limited stock.
Many modern DTG printing machines are designed with sustainability in mind, utilizing advanced technology that minimizes waste and energy consumption. The inks used in DTG printing are typically water-based and free from hazardous chemicals, offering a more eco-friendly option than some traditional printing methods.
Screen printing, while effective for large runs, often contributes to more waste due to its focus on bulk production. Unsold inventory can lead to textile overproduction, which is one of the primary issues in the sustainable fashion movement.
Additionally, screen printing requires significant water usage and the use of chemical solvents during the cleaning process. Each screen needs to be washed after use, which results in higher water consumption and more chemical waste.
As businesses and consumers alike become more aware of the environmental impact of their practices, it’s important to evaluate the sustainability of each printing method.
On-Demand Fulfillment
DTG printing stands out as the best option for on-demand fulfillment. With minimal setup time, businesses can print individual items or small batches without requiring significant upfront investment. This makes DTG printing ideal for online stores that are linked to print-on-demand fulfillment services, where products are printed only when they are ordered.
When a customer places an order for a single item, the fulfillment service automatically processes the order, prints the design on the product, and ships it directly to the customer with the store’s branding. This process is seamless and highly efficient for businesses that do not wish to maintain large inventories or carry the costs associated with bulk ordering.
However, businesses that need to place bulk orders for specific needs can still do so. Many print providers offer discounted rates for larger quantities, making it a flexible option for varying production requirements.
In contrast, screen printing generally involves higher setup costs and requires minimum order quantities, making it better suited for large, one-time orders rather than on-demand production. This reduces flexibility for businesses that prefer not to deal with surplus stock.
If you are considering screen printing for a bulk order, it’s important to note that you can request a quote, which is typically provided within 48 hours, to assess the cost of large quantities.
Upfront Investment
The cost of screen printing is influenced by the number of items ordered. For large quantities, screen printing can be the most cost-effective option. This is because the preparation of screens, which is a time-consuming process, is more economical when spread across a larger number of items. Bulk orders benefit from this, as the cost per item decreases significantly. However, when it comes to ordering small quantities or a single product, DTG printing is the more budget-friendly choice.
Screen printing can be economically viable for designs that are simple and have few colors. However, the initial investment is substantial. Most print providers that offer screen printing require a minimum order, often ranging from 5 to 100 items, depending on the supplier.
Additionally, the final price of screen printing for bulk orders is influenced by the number of colors in the design, as each color typically requires a separate screen. This means that if your design involves multiple colors, the costs will be higher. This can make screen printing less financially viable for those just starting their business or experimenting with different designs.
Ordering in bulk also creates storage challenges. If you don’t want large quantities of printed garments cluttering your space, you’ll need to arrange for appropriate storage, which can limit your product variety. Since each design must be printed in bulk, your store’s offerings may be limited in terms of design diversity.
DTG vs. Screen Printing: When to Choose Each Method?
Each printing method has its advantages, depending on the type of design and the scale of production. Understanding when to use each technique will help you make the most informed decision about which one aligns with your needs.
When to Choose DTG Printing
DTG printing is the ideal choice for designs that are intricate, feature photorealistic images, or require a wide color palette. It is also the best option if you want to print small quantities or offer personalized apparel on demand. For businesses that frequently update their designs or offer a wide variety, DTG printing provides flexibility without the need for significant upfront investment or the burden of storing excess inventory.
DTG printing allows you to easily scale your business, experiment with different designs, and make changes without being locked into large production runs. Its low minimum order requirements and on-demand printing make it perfect for small businesses or those with diverse product offerings.
When to Choose Screen Printing
Screen printing is ideal for simpler, bolder designs that use solid colors and do not require intricate details. It is especially well-suited for large production runs, where the cost per item is reduced due to the efficiency of bulk printing. If your design involves basic graphics or text and you need to print a large quantity of items in a cost-effective manner, screen printing is the most appropriate choice.
It’s also the go-to option when you need to produce a large number of items quickly, making it highly suitable for events, promotions, or large-scale retail orders.
As evident from the comparison, there is more than just time and money to consider when selecting the right printing technique for your business.
Choose Your Printing Method Wisely
Whether you opt for DTG printing or screen printing depends on your specific business needs. Before making a decision, consider the following factors:
- Your brand image
- The complexity of your designs
- Your product quantity requirements
- Your willingness to invest in stock upfront
If your goal is to grow your business with minimal risk and effort, on-demand DTG printing is likely the best choice. With DTG printing, you can easily introduce new designs to your store without the need for large orders or inventory management. This allows you to focus more on product development, marketing, and customer engagement rather than worrying about stock levels.
Using DTG printing also helps eliminate overproduction, reducing waste and supporting more sustainable business practices.
