Printing Methods Compared

Screen printing uses ink pushed through mesh screens — one screen per color. It's faster per piece on bulk orders, has thicker ink with better durability, but has color limits (typically 1–6) and setup time per design.

DTG (direct-to-garment) prints digital ink directly onto fabric like an inkjet printer. It handles unlimited colors and photo-quality detail.

The general crossover point is around 25 pieces — under that, DTG often wins on cost; above that, screen printing usually wins. However, if your design is a photo, has gradients, or uses too many colors for screen printing, DTG is the right choice at any quantity — including bulk orders.

DTF (direct-to-film) prints your design onto a special film, then heat-transfers it onto the garment. It produces vibrant, full-color prints that work on virtually any fabric — cotton, polyester, blends, nylon, even leather.

Choose DTF when: you need full color on a fabric that doesn't work well with DTG, you have small to mid-size orders (1–100 pieces), or you want consistent quality on hard-to-print materials like performance wear.

Embroidery is the most durable — stitched thread doesn't crack, peel, or fade and lasts the lifetime of the garment. Screen printing is next, with quality plastisol prints lasting 50+ wash cycles when cared for properly. DTF is comparable to screen printing in durability when applied correctly. DTG holds up well but can fade slightly faster than screen printing on dark garments.

Care matters more than method — turning inside out, cold wash, and air-drying extends life for any decoration type.

It depends on quantity and design complexity. For 1–24 pieces with full-color or photo designs, DTG is usually cheapest. For 25+ pieces with simple designs (1–6 colors), screen printing is usually cheapest.

For photo or full-color designs, DTG remains the right choice at any quantity since screen printing can't replicate that detail. DTF works well for small to mid-size full-color runs on tricky fabrics. Embroidery is more expensive per piece but justified for premium products and brand-quality logos.

Setup fees are always free with us.

Yes. Many of our customers combine methods on a single garment — for example, embroidered chest logo + screen printed back graphic, or DTF heat transfer for a small detail + screen print for the main design. Combining methods costs more than a single method but creates a layered, premium look. Tell us what you're going for and we'll recommend the best combination.

All four methods work on dark garments, but with different processes:

Screen printing on dark fabrics requires a white underbase, which adds a print pass but produces vibrant results. DTG also requires a white underbase on darks (we handle this automatically). DTF prints with full opacity on any color without requiring an underbase, making it efficient for dark fabrics. Embroidery is unaffected by garment color since thread is opaque.

Embroidery is the standard for hats and caps — it's structured, professional, and durable. Screen printing on hats is technically possible but rarely done due to curved surfaces. DTF transfers can work on flat-front hats and bring full-color capability that embroidery can't match. DTG doesn't work on hats. For most hat orders, embroidery is the right choice.

Embroidery is the gold standard for polos. The structured stitched logo on a chest or sleeve looks premium and professional, ideal for corporate uniforms, golf wear, and team apparel. Screen printing on polos is uncommon but possible. DTG works on cotton polos. DTF can produce full-color logos on polos when embroidery's color limitations don't fit your design.

We digitize your logo for free on new embroidery orders.

Sublimation uses heat to convert solid dye into gas, which permanently bonds with polyester fibers. The result is a print that becomes part of the fabric — no ink layer to feel, crack, or peel.

Choose sublimation when: you're decorating polyester or polyester-coated items (like performance jerseys, athletic wear, or mugs), you want all-over prints that cover the entire garment, or you need photo-quality graphics that will never fade. Sublimation does NOT work on cotton fabrics or dark-colored garments.

Sublimation dye chemically bonds only with polyester fibers — it cannot bond with cotton or natural fibers. On cotton, the dye simply washes out.

Sublimation also requires a light or white base since the dye is translucent; on dark fabrics, the design wouldn't be visible because the fabric color shows through. For dark cotton or mixed fabrics, DTF or screen printing are better choices.