Comparing Direct-to-Garment and Screen Printing for Custom Shirts

When creating custom shirts, you’re faced with a choice between two primary printing techniques: direct-to-garment (DTG) printing and screen printing. Each method offers unique advantages and drawbacks, so understanding the differences is crucial for selecting the best option for your needs.

Process and Equipment

Direct-to-Garment (DTG) Printing: DTG printing involves injecting ink directly onto the fabric using a specialized printer. The process is remarkably similar to printing on paper, with the printer translating a digital image into a physical design on the garment.

Screen Printing: Screen printing, on the other hand, uses a stencil process. A screen (typically made of mesh) is coated with a light-sensitive emulsion. The image is transferred to the screen using light, and the unexposed emulsion is washed away. The ink is then forced through the screen onto the fabric.

Image Quality

Direct-to-Garment (DTG) Printing: DTG printing produces high-quality images with vibrant colors and intricate details. It’s particularly well-suited for complex designs with gradients and blended colors. However, the print texture may be slightly raised, especially on darker fabrics.

Screen Printing: Screen printing excels in delivering bold, opaque prints with sharp lines and edges. The print texture is generally flat and smooth, making it ideal for simpler designs with fewer colors.

Fabric Compatibility

Direct-to-Garment (DTG) Printing: DTG printing can be used on a wide range of fabrics, including cotton, polyester, and blends. However, it’s most effective on lighter-colored fabrics, as darker fabrics may absorb the ink and result in a less vibrant print.

Screen Printing: Screen printing is suitable for various fabrics, including cotton, polyester, canvas, and even leather. The choice of fabric primarily depends on the ink type used.

Durability and Longevity

Direct-to-Garment (DTG) Printing: DTG prints are generally less durable compared to screen printing. They may fade or crack over time, especially when exposed to frequent washing.

Screen Printing: Screen prints are known for their exceptional durability and longevity. They can withstand multiple washes and harsh conditions without significant fading or cracking.

Production Time and Cost

Direct-to-Garment (DTG) Printing: DTG printing is ideal for small orders with quick turnaround times. It’s relatively simple to set up and print individual garments on demand. However, the cost per print can be higher for smaller quantities.

Screen Printing: Screen printing requires more extensive setup and preparation, making it more efficient for larger orders. The initial investment in screens and inks can be substantial, but the cost per print decreases as the quantity increases.

Environmental Impact

Direct-to-Garment (DTG) Printing: DTG printing uses water-based inks, which are more environmentally friendly than plastisol inks used in screen printing. The printing process also produces less waste.

Screen Printing: Screen printing typically employs plastisol inks, which are oil-based and can contribute to environmental pollution. However, eco-friendly water-based plastisol inks are available.