Screen Printing vs DTG Which One Is Better for T-Shirts?

When it comes to printing custom T-shirts, two of the most popular methods are screen printing and direct-to-garment (DTG) printing. Both techniques have their own advantages and limitations, making it essential to understand which one suits your needs better. Whether you’re a small business owner, a brand looking for bulk orders, or an individual wanting a custom design, this guide will help you choose the right printing method.

What Is Screen Printing?

Screen printing, also known as silk screen printing, is a traditional method that involves pushing ink through a mesh screen onto the fabric. Each color in the design requires a separate screen, making the process labor-intensive but highly efficient for bulk orders.

Pros of Screen Printing

• Durability and Vibrancy – Screen-printed designs are long-lasting and resistant to fading, cracking, or peeling. The thick ink application ensures a bold and vibrant print.
• Cost-Effective for Bulk Orders – Since screens are reused for multiple prints, screen printing becomes cheaper per unit when ordering in large quantities.
• Works Well on Various Fabrics – This method is versatile and can be applied to cotton, polyester, blends, and even specialty materials like performance fabrics.
• Customization with Special Effects – You can achieve unique effects such as metallic, glow-in-the-dark, and raised puff prints, which are difficult to replicate with DTG.

Cons of Screen Printing

• High Setup Costs – The initial setup requires making separate screens for each color, making it expensive for small batches.
• Limited Color Options – Each additional color increases the complexity and cost, making it less suitable for designs with many shades or gradients.
• Less Detail Precision – Fine details and intricate patterns may not be as sharp as with DTG printing.

What Is Direct-to-Garment (DTG) Printing?

DTG printing is a modern digital method where ink is sprayed directly onto the fabric using a specialized printer. It works similarly to an inkjet printer, allowing for highly detailed designs with an unlimited range of colors.

Pros of DTG Printing

• High Detail and Color Accuracy – DTG printing can handle complex designs, including gradients, shadows, and intricate details, making it ideal for photorealistic images.
• No Setup Costs – Unlike screen printing, DTG does not require screens or stencils, making it a cost-effective choice for small orders and one-off prints.
• Eco-Friendly – DTG printers use water-based inks, which are generally more environmentally friendly than traditional plastisol inks used in screen printing.
• Fast Turnaround Time – Since no screens need to be created, DTG printing allows for on-demand production and quick fulfillment of custom orders.

Cons of DTG Printing

• Less Durability Compared to Screen Printing – While DTG prints can last a long time with proper care, they tend to fade faster than screen-printed designs, especially after multiple washes.
• Higher Cost Per Unit for Bulk Orders – Because DTG prints each T-shirt individually, the cost does not decrease significantly with large quantities, making it less economical for mass production.
• Limited Fabric Compatibility – Works best on 100% cotton garments. DTG may not perform as well on polyester or blended fabrics.
• Requires Special Pretreatment – To ensure the ink adheres properly, dark-colored garments need to be pretreated, adding an extra step to the production process.

Key Differences Between Screen Printing and DTG

Which One Should You Choose?

The best printing method depends on your specific needs:

• Choose Screen Printing If:

• You need a large quantity of T-shirts (50+ pieces).
• Your design uses only a few solid colors.
• You want a durable print that can withstand frequent washes.
• You’re printing on various types of fabrics.

Choose DTG Printing If:

• You need a small batch or a single custom T-shirt.
• Your design is complex with multiple colors and gradients.
• You want a quick turnaround for on-demand orders.
• Your garments are primarily 100% cotton.

Cost Comparison: Screen Printing vs. DTG

While exact pricing varies by location and provider, here’s a general breakdown:

• Screen Printing Costs
  • Setup Fee: $20–$50 per color
  • Per T-Shirt Cost: $5–$10 (depends on quantity and design)
  • Best for: Orders of 50+ shirts
• DTG Printing Costs
  • No setup fee
  • Per T-Shirt Cost: $10–$25 (higher for dark-colored shirts due to pretreatment)
  • Best for: Small orders (1–10 shirts)

Which Printing Method Is More Profitable for a Business?

If you’re running a custom T-shirt business, the choice between screen printing and DTG depends on your business model:

• For Bulk Orders and Wholesale Business: Screen printing offers better margins due to lower costs per unit.
• For Print-on-Demand and Custom Orders: DTG is more suitable because it allows flexibility without requiring inventory.

Many businesses combine both methods—using screen printing for large orders and DTG for personalized, one-off designs.

Conclusion

Screen printing and DTG each have their strengths and weaknesses. If you prioritize cost-effectiveness, durability, and bulk production, screen printing is the better choice. However, if you need high-detail prints, on-demand flexibility, and a wide color range, DTG printing is the way to go.

By understanding your specific needs and target market, you can choose the best method to create high-quality custom T-shirts that meet your business or personal goals.

Mia Wilson

Hi, I’m Mia Wilson, a fashion blogger with over six years of experience in the industry. Based in the United States, I’ve dedicated my career to exploring and sharing the world of fashion through my blog. I’m passionate about discovering the latest trends, offering style tips, and promoting sustainable fashion choices. My journey in the fashion blogging world has been an exciting adventure, and I’m thrilled to continue inspiring others to express their unique style.