T-Shirt Printing Methods Compared: Screen, DTF, DTG

Key takeaways

Screen printing is cheapest per piece for bulk orders of about 50+ with limited colours.
DTF has no minimums and prints full colour on cotton, polyester and blends.
DTG suits detailed designs on 100% cotton; sublimation works only on light polyester.
Embroidery is the most professional and durable choice for polos and workwear.
Halftoning makes large digital prints softer and more breathable.

Introduction

The decoration on a T-shirt is what turns a plain garment into a brand, a message or a memory. It is also where many orders go wrong. A photo-realistic design screen printed in eight colours on fifty shirts will cost a fortune. A large solid block printed by DTF on a light shirt can feel like a plastic sheet. A fine-detail logo embroidered too small turns into a blur of thread.

Each decoration method has a sweet spot: a type of design, a quantity range, a fabric and a budget where it performs best. The custom T-shirt printing market, valued by different research firms at between about US$6 billion and US$9 billion in 2025, is growing partly because digital methods have made small runs affordable. But traditional screen printing remains the workhorse for bulk orders.

This article compares the main methods: screen printing, DTF, DTG, embroidery, heat-transfer vinyl, sublimation and specialty finishes. It explains how each works, its strengths and limits, and how to choose.

Screen printing

How it works

A separate mesh screen is made for each colour in the design. The stencil on each screen allows ink through only where that colour should print. Ink is pushed through the mesh with a squeegee onto the garment, one colour at a time, and the print is then cured with heat.

For dark garments, a white underbase is printed first so that colours on top stay bright.

Inks

Plastisol: the most common ink. It sits on top of the fabric, gives bright, opaque colours on any shirt colour, and is very durable. The print has a slightly raised, smooth feel.
Water-based: soaks into the fibres for a soft, breathable print with almost no feel. Best on light, natural-fibre garments.
Discharge: removes the garment’s dye and replaces it with colour, giving soft, bright prints on dark cotton. It works only on suitable dyed cotton and needs careful testing.

Strengths

Lowest cost per print for larger quantities.
Very durable, often outlasting the garment.
Exact Pantone colour matching.
Special effects available, including puff, metallic, glitter, glow-in-the-dark and high density.

Limits

Setup cost for each colour, so small orders and many-colour designs are expensive.
Photographs and smooth gradients need halftone separation and skilled printers.
Each design or colour change means new screens.

Best for

Bulk orders of 50 pieces or more with designs of up to about six colours, such as staff uniforms, events, merchandise and retail lines.

DTF (direct to film)

How it works

The design is printed with special inks onto a PET film, including a white layer behind the colours. A powdered adhesive is applied while the ink is wet, then melted. The finished transfer is heat-pressed onto the garment and the film is peeled away.

Teepig, which uses DTF for its online orders, describes the method as printing on film and heat-pressing it with a solid white base under the colours. That white base makes colours vivid on any garment colour.

Strengths

No minimum order and no screen setup, so one shirt costs about the same per print as fifty.
Full colour, fine detail and photographs.
Works on cotton, polyester and many blends, as Teepig notes.
Transfers can be printed in advance and pressed on demand.

Limits

Large solid areas can feel heavy and less breathable. Teepig warns that big, blocky designs can feel like a stiff sheet on thin T-shirts.
Very thin lines and small text may not bond well. Teepig recommends a minimum text size of 14pt and avoiding very thin lines, because the glue needs enough surface area.
Semi-transparent pixels print poorly, because the white underbase shows through.

Making DTF prints softer

Teepig uses halftoning to solve the heavy-print problem. Large prints and gradients are broken into tiny dots of varying size, which removes unnecessary solid ink, lets the fabric show through and makes the print softer and more breathable. It applies this free of charge on large prints. Dsigngo’s design team applies the same technique when preparing artwork for DTF.

Best for

Small runs, full-colour designs, personalised names, mixed fabrics and fast turnaround.

DTG (direct to garment)

How it works

A specialised inkjet printer prints water-based inks directly onto the garment. Dark garments are first sprayed with a pre-treatment so that the white ink bonds and stays bright.

Strengths

Photographic detail and unlimited colours.
Very soft feel on light garments, because the ink soaks into the fibres.
No screens, so it suits single pieces and print-on-demand.

Limits

Works best on 100% cotton. Results on polyester and blends are weaker.
Slower per piece than screen printing, so bulk orders cost more.
Colours on dark garments can be less vivid than screen printing, and durability depends on correct curing.

Best for

Small runs and one-offs of detailed designs on cotton, and online print-on-demand stores.

Embroidery

How it works

The design is converted into a stitch file by a process called digitising, which decides stitch types, directions and density. Computer-controlled embroidery machines then stitch the design in thread. A backing (stabiliser) is used behind the fabric to prevent puckering.

Teepig, for example, embroiders in-house with up to six thread colours and charges a one-off digitising fee from £12 per logo.

Strengths

Premium, professional look that suits corporate wear.
Extremely durable, lasting as long as the garment.
Texture and dimension that print cannot match.
The digitised file can be reused for repeat orders.

Limits

Not suitable for fine detail, small text or photographs.
Price depends on stitch count, so large designs are expensive.
Can pucker on light jersey fabrics. Piqué polos and heavier T-shirts give the best results.

Best for

Logos on polo shirts, workwear, caps, hoodies and premium T-shirts, usually on the left chest, sleeve or back neck.

Heat-transfer vinyl (HTV)

How it works

Designs are cut from coloured vinyl sheets with a plotter, the excess is removed (weeded), and the design is heat-pressed onto the garment.

Strengths

Ideal for names and numbers on team shirts.
Special finishes such as glitter, metallic, reflective and flock.
No minimum quantity.

Limits

Best for simple shapes and text, with one or two colours per design.
Each piece is weeded by hand, so complex designs take time.
Can feel heavy on large areas.

Best for

Sports kits, personalisation and small runs of simple designs.

Sublimation

How it works

Designs are printed with sublimation inks onto transfer paper, then heat-pressed. The heat turns the ink into a gas that bonds with polyester fibres, so the design becomes part of the fabric.

Strengths

Full-colour, edge-to-edge (all-over) prints.
No feel at all, because there is no ink layer.
Excellent wash durability and breathability.

Limits

Works only on polyester or high-polyester fabrics.
Only on white or very light garments, because sublimation ink is transparent and cannot print white.
Small white creases can appear in all-over prints where the fabric folds during pressing.

Best for

Sports jerseys, running event shirts and all-over printed polyester garments.

Specialty finishes

Puff: an additive makes the ink rise when cured, giving a raised 3D effect.
High density: thick, sharp-edged prints built up with special screens.
Metallic and foil: shiny gold, silver and other effects. Foil is applied with heat over an adhesive print.
Glitter: sparkle effects in ink or vinyl.
Reflective: for safety wear and running events.
Glow-in-the-dark: for events and children’s wear.
Woven and printed patches: sewn or heat-applied, popular for premium and streetwear brands.

Side-by-side comparison

Method	Best quantity	Colours	Feel	Durability	Fabrics
Screen printing	50+	Up to about 6 spot colours	Smooth to soft	Excellent	Most
DTF	1+	Unlimited	Medium; softer with halftone	Very good	Cotton, polyester, blends
DTG	1+	Unlimited	Very soft on light shirts	Good	Best on cotton
Embroidery	10+	Up to about 6–12 threads	Textured	Excellent	Stable fabrics
Vinyl	1+	1–2 per design	Smooth, firmer	Very good	Most
Sublimation	1+	Unlimited	None	Excellent	Polyester, light colours only

How to choose: questions to ask

How many shirts? Under about 50 pieces, digital methods usually win. Over that, screen printing becomes cheaper per piece.
How many colours? A one or two-colour logo suits screen printing or embroidery. Photographs suit DTF, DTG or sublimation.
What garment colour? Dark garments need a white underbase (screen, DTF) or pre-treatment (DTG). Sublimation cannot be used.
What fabric? Cotton suits most methods. Polyester rules out DTG and favours sublimation, DTF or suitable screen inks.
How should it feel? For a soft, breathable feel, choose water-based screen printing, discharge, DTG or halftoned DTF.
How long must it last? For uniforms washed weekly, screen printing and embroidery are the most durable choices.
Is each shirt different? Names, numbers or individual photos call for vinyl, DTF or DTG.

Placement and print sizes

Common print positions include:

Full front: a typical adult front print is about 24cm wide by 36cm tall, according to Teepig’s guidelines, with a DTF maximum of 29.7cm by 40cm.
Left chest: usually 8–10cm wide, ideal for logos and embroidery.
Full back: similar size to the full front, often used for event names and sponsor lists.
Back neck: a small logo or website address below the collar.
Sleeve: a small logo, flag or text on the upper sleeve.
Hem or side: a small tag-style print near the bottom edge.

Placement should be checked on every size. A 28cm-wide print that looks right on an XL can wrap around the sides of an XS. For large orders, two print sizes may be needed.

Durability and care

Even the best print lasts longer with proper care. Teepig’s advice is to wash at 30°C or lower, avoid tumble drying and never iron directly over the print. Turning shirts inside out before washing also reduces abrasion. For uniforms washed at higher temperatures, embroidery and well-cured plastisol prints are the safest options.

How decoration is priced

Understanding how decoration is priced helps you design artwork that fits your budget.

Screen printing

Screen printing has two cost parts: a setup cost for each colour in each position (screens, films and press setup), and a running cost per print. Because setup is spread over the order, the price per shirt falls quickly as quantity rises. A design with three colours on the front and one on the back needs four screens in total.

Ways to reduce cost:

Fewer colours: a two-colour design often looks stronger and costs much less than a six-colour version.
Fewer positions: each extra print position adds setup and handling.
Same design, several shirt colours: the screens can be reused, although ink colours may need adjusting for dark and light garments.
Repeat orders: some printers store screens or artwork, reducing setup on reorders.

DTF and DTG

Digital methods have little or no setup cost. Price depends mainly on print size and, for DTF, the area of film used. That makes them ideal for small runs, many designs or personalised shirts, but the cost per piece falls more slowly as quantity rises.

Embroidery

Embroidery is priced by stitch count. A small left-chest logo might be around 5,000–8,000 stitches, while a large back design can run to tens of thousands. Digitising is a one-off charge. Teepig, for example, charges from £12 for logo digitising, and the file is then reused for future orders.

Colour matching

Brand colours matter, especially for corporate wear. Each method handles colour differently:

Screen printing mixes inks to Pantone references, giving the most accurate spot colour match.
DTF and DTG print with CMYK inks plus white. Teepig points out that screens show RGB light while printers use CMYK ink, so very bright neon colours print more muted. Exact brand colours should be discussed before ordering.
Embroidery uses thread colour charts. The nearest thread colour is chosen to match the brand colour, and thread sheen makes colours look slightly different from print.
Sublimation can achieve very bright colours on white polyester, but colours shift slightly with heat and fabric.

Always approve a physical sample for brand-critical colours. A colour that looks perfect on a monitor can look different on a cotton shirt in daylight.

Quality checks for decorated garments

Dsigngo checks decorated garments for:

Position: print or embroidery placed within tolerance, usually measured from the collar seam and centre front.
Registration: colours lined up correctly in multi-colour screen prints.
Coverage: no pinholes, thin areas or smudges.
Curing: a stretch test checks that ink does not crack when the fabric is pulled, and a wash test confirms adhesion.
Embroidery: no loose threads, puckering or gaps, and backing trimmed neatly.
Cleanliness: no ink marks, adhesive residue or press marks on the garment.

Print and wash testing is the fourth of Dsigngo’s five quality gates for apparel.

Greener decoration choices

Decoration has an environmental side too:

Water-based inks contain no PVC and give soft, breathable prints. They need careful handling and suit natural fibres.
PVC-free and phthalate-free plastisol alternatives are now widely available, and many brands and certifications require them.
Digital printing uses ink only where needed and avoids screen washing chemicals, which suits small runs.
Durable decoration is the greenest option of all, because a shirt whose print survives keeps being worn.

If your brand needs certified decoration, for example for a GOTS or OEKO-TEX product, the inks and processes used must meet that standard’s requirements.

An example in practice

The following example is illustrative and does not describe a real client.

A Kandy school plans a sports meet with four houses, 800 students and 60 staff. The house T-shirts use screen printing: one design in four house colours, 200 pieces each, keeping cost per piece low. Staff polos carry an embroidered school crest on the left chest. Relay team captains get their names and numbers on the back in heat-transfer vinyl. Commemorative shirts for the organising committee, printed with a full-colour photo collage, use DTF with halftoning so they stay comfortable in the heat.

How Dsigngo Group helps

Dsigngo Group offers T-shirt decoration, supported by an in-house design team that prepares print-ready artwork, colour separations and embroidery files. We recommend the decoration method based on your design, quantity, fabric and budget, and provide a sample before bulk production.

Frequently asked questions

Which printing method lasts longest?

Screen printing and embroidery are usually the most durable. Sublimation also lasts very well on polyester.

What is the cheapest way to print 20 shirts?

Usually DTF or vinyl, because there are no screen setup costs. For a single-colour design, screen printing may still compete.

Can you print photographs on T-shirts?

Yes, using DTF, DTG or sublimation. Photos print best on white garments, as Teepig notes.

Can embroidery go on a T-shirt?

Yes, with a suitable stabiliser and a heavier fabric. Small, simple logos work best.

Why do some prints crack?

Usually because of under-curing, a thick ink layer on stretchy fabric, or hot washing and tumble drying.

Conclusion

No single decoration method is the best. Screen printing wins on bulk cost and durability, DTF and DTG on flexibility, embroidery on prestige, vinyl on personalisation and sublimation on all-over colour. Match the method to the design, quantity, fabric and purpose, and test a sample first, and your T-shirts will look as good after fifty washes as on day one.

Not sure which method suits your design? Ask Dsigngo Group for a recommendation and a sample.

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