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Direct-to-Garment (DTG) printing is a modern method that uses inkjet technology to print full-colour designs directly onto fabric. It works best on 100% cotton garments and allows for detailed, photo-quality prints. DTG is ideal for short runs, custom orders, and designs with lots of colours or gradients.
Screen printing is a traditional method that uses a mesh stencil to apply layers of ink onto garments. It’s best for bold designs with solid colours and works well on both cotton and polyester fabrics. Screen printing is cost-effective for large orders due to its durability and vibrant finish.
Here are the differences between screen printing and DTG:
1. Artwork Complexity & Colour Handling
- DTG: Excels with intricate, multicolour, photorealistic designs (e.g., photos, gradients). Applies all colours simultaneously with no separation needed. No practical limit on colours.
- Screen Printing: Best suited for simpler designs with solid fills (e.g., bold logos, text). Each colour requires a separate screen, making high-colour-count or highly detailed designs significantly more complex and costly.
2. Fabric Suitability & Pretreatment
- DTG: Optimal on 100% cotton or high-cotton blends. Requires chemical pretreatment for dark garments to ensure vibrancy and adhesion. Limited effectiveness on pure synthetics.
- Screen Printing: Highly versatile across fabrics (cotton, polyester, nylon, blends, performance wear). No pretreatment needed. Plastisol inks (common in screen printing) perform exceptionally well on synthetics and darks.
3. Setup Process & Production Efficiency
- DTG: Minimal setup (digital file upload). Near-instant switching between designs. Ideal for single items or small batches. Enables true print-on-demand (POD).
- Screen Printing: Significant setup time (screen creation, colour separation, registration). Efficient only for larger runs of the same design due to setup amortization. Design changes require new setups.
4. Cost Structure
- DTG: Low upfront investment (printer). Minimal setup cost per design. Consistent cost per unit regardless of colour count or order size. Economical for low-volume/custom orders.
- Screen Printing: Higher upfront investment (screens, exposure unit, press). Setup cost incurred per colour. Cost per unit decreases significantly with volume but increases with colour count. Economical only for medium-large runs.
5. Print Characteristics: Appearance, Feel & Durability
- DTG: Water-based inks absorb into fabric, resulting in a soft, breathable hand feel (“feels like the shirt”). Excellent detail reproduction. Good wash durability on properly cured cotton. Vibrant colours on pretreated darks; softer vintage look possible.
- Screen Printing: Ink (typically plastisol) sits on top of the fabric in thicker layers, creating a more tactile, slightly raised feel. Exceptionally bold colours and opacity, especially on darks without pretreatment. Superior long-term abrasion resistance and colour vibrancy under heavy wear/washing. Crisp edges on solid elements.
6. Inventory & Business Model Impact
- DTG: Enables pure print-on-demand. Zero inventory risk – produce only what’s sold. Ideal for customisation, small businesses, and online stores with vast design libraries.
- Screen Printing: Requires batch production and inventory holding. Capital tied up in unsold stock. Best for predictable demand, bulk orders (uniforms, event merch, promotions).
7. Sustainability Considerations
- DTG: Lower waste potential via POD (no overstock). Modern water-based inks and efficient printers reduce water/energy use vs older methods. Requires pretreatment (chemical use).
- Screen Printing: Chemical use (emulsions, screen reclaimers, plastisol cleaners) and water consumption during cleanup are primary impacts. Waste is generated from overproduction. Plastisol ink disposal requires care. Efficient large runs minimise per-unit impact.
8. Best Use Case
- Choose DTG For: Low-volume orders (1-50+), highly customised items, designs with many colours/photorealism, 100% cotton garments, print-on-demand businesses, rapid prototyping.
- Choose Screen Printing For: High-volume runs (100+), simple designs with limited colours (<6 ideal), garments needing maximum durability (workwear, uniforms), performance/synthetic fabrics, bold opaque prints on darks, consistent repeat orders.
Screen printing and DTG (Direct-to-Garment) are both popular apparel printing methods, but they serve different needs. Screen printing is best for high-volume orders with bold, simple designs and limited colours, offering long-lasting, vibrant prints on a wide variety of fabrics—including synthetics—making it ideal for uniforms, workwear, and event merch. However, it requires setup time, minimum quantities, and generates more waste. DTG, on the other hand, is perfect for small runs or one-off orders with complex, multi-colour or photo-realistic designs, especially on 100% cotton garments. It produces soft, detailed prints with no setup costs, making it great for print-on-demand and sustainable business models.
DTG vs. Screen Printing: Quick Comparison
This table compares DTG and screen printing across key features, including design complexity, fabric compatibility, setup & turnaround, cost efficiency, print feel & durability, inventory model, sustainability, and best use cases, helping you choose the right method for your project.
| Feature | DTG Printing | Screen Printing |
| Design Complexity | Great for detailed, multi-colour or photo-like designs. | Best for simple, bold designs with few colours. |
| Fabric Compatibility | Ideal for 100% cotton and blends; not suitable for synthetics. | Works on cotton, polyester, nylon, and performance fabrics. |
| Setup & Turnaround | Minimal setup; fast design changes; perfect for small runs and POD. | Time-consuming setup; efficient for large, repeat orders. |
| Cost Efficiency | Fixed cost per unit; cost-effective for low-volume or custom orders. | Lower per-unit cost at high volumes; setup adds cost for complex or colourful designs. |
| Print Feel & Durability | Soft, breathable prints; good detail and wash resistance. | Raised, durable prints; bold colour and long-term wear resistance. |
| Inventory Model | On-demand production; no inventory needed. | Requires stock; better for bulk planning. |
| Sustainability | Lower waste; water-based inks; eco-friendly tech. | More waste and chemical use; higher water consumption. |
| Best For | POD stores, personalised designs, small batch apparel. | Events, uniforms, promotional gear, high-volume runs. |
Artwork Complexity & Colour Handling
DTG (Direct-to-Garment) printing is unmatched when it comes to reproducing complex, multi-colour, or photorealistic designs. Whether it’s detailed artwork, gradients, shading, or high-resolution photographs, DTG handles it all with ease because the design is printed directly from a digital file—no screens, layers, or colour separations required. This means all colours are applied simultaneously in a single pass, allowing for unlimited colour use without impacting setup time or cost. As a result, DTG is ideal for brands or businesses offering customised designs, product personalisation, or small-batch artistic prints where every detail matters.
Screen printing, in contrast, is better suited to clean, bold graphics such as logos, text, or geometric shapes with limited colour usage. Each colour in a design requires its own screen, and the inks are layered manually during printing. This setup makes screen printing time-consuming and costly for designs with numerous colours or fine details. Intricate artwork also risks losing definition through the stencil and mesh process. Therefore, screen printing is most efficient for simple, high-contrast designs and becomes less practical for designs involving gradients, subtle tones, or more than 6–9 colours.
Fabric Suitability & Pretreatment
DTG printing works best on 100% cotton or high-cotton blend fabrics, where its water-based inks can properly absorb into the fibres to deliver soft, long-lasting prints. For dark garments, a pretreatment solution is applied beforehand to create a white underbase—this step ensures colour vibrancy and proper ink adhesion. While DTG can produce excellent results on cotton-rich fabrics, it performs poorly on pure synthetics like polyester, where ink adhesion is limited and colour vibrancy may suffer.
Choose Smart. Print Sharp.
Screen printing, in contrast, is far more flexible when it comes to fabric types. It’s compatible with cotton, polyester, nylon, and various blends, making it ideal for a wide range of garments—including athletic and performance wear. No pretreatment is needed, and the inks used (especially plastisol) sit on top of the fabric, allowing for bright, high-opacity prints even on dark materials. This versatility makes screen printing a reliable choice for printing across diverse fabric types with consistent, bold results
Setup Process & Production Efficiency
DTG printing offers a fast and flexible setup process—designs are uploaded digitally and sent directly to the printer, with no physical preparation or screens required. This makes it ideal for printing one-off items or fulfilling small orders on demand, as each garment can be customised and printed with minimal turnaround time. The ability to switch between designs instantly allows for true print-on-demand (POD) workflows, making DTG a perfect fit for online stores and e-commerce brands offering personalised or limited-run apparel.
Screen printing, by comparison, requires a more complex and time-intensive setup. Each colour in the design needs a separate screen, and proper registration is essential to ensure alignment. This makes it inefficient for small orders or custom runs, as the setup time and cost can’t be spread across a few units. Instead, screen printing shines in larger production runs, where the initial investment is offset by printing hundreds or thousands of identical items. However, any design change—no matter how small—means starting the setup process all over again, which limits its flexibility in dynamic or personalised product environments.
Cost Structure
DTG printing involves a relatively low upfront investment, with minimal setup required for each design. Since it operates digitally, there’s no cost associated with colour separation or screen creation, making the cost per unit consistent regardless of the number of colours used or the size of the order. This predictability makes DTG an economical choice for low-volume runs, custom pieces, and businesses experimenting with multiple designs or testing the market. It’s especially suitable for startups, artists, or online stores offering personalised apparel without holding excess inventory.
Screen printing or DTF— Which printing method is better?
Screen printing and DTF (Direct-to-Film) are both versatile printing methods, but they differ in flexibility and application. Screen printing is a long-standing favourite for high-volume orders, delivering vibrant, long-lasting colours on cotton and polyester, though it requires separate screens for each colour. DTF, a newer digital method, prints designs onto a film that’s then heat-pressed onto fabric, allowing for intricate, full-colour designs on a wider range of materials (including blends and synthetics) with minimal setup. While screen printing is more cost-effective for bulk runs, DTF offers quicker turnaround and more detail for small batches or complex designs.
Should you choose screen printing or embroidery for branded work uniforms?
Screen printing and embroidery are both popular garment decoration methods, but they serve different purposes. Screen printing excels in bold, colourful designs on fabrics like cotton and polyester, making it ideal for large orders with simple to moderately complex artwork. Embroidery, on the other hand, creates a textured, high-end finish with thread stitching, perfect for logos, uniforms, and premium apparel—especially on thicker fabrics like polos, hats, and jackets. While screen printing is faster and more cost-effective for bulk orders, embroidery offers unmatched durability and a professional look.
Budget-Friendly Printing Starts Here.
Screen printing, on the other hand, comes with a higher initial investment due to the need for screens, an exposure unit, and a press. Each colour in the design adds to the setup time and cost, as separate screens must be created and aligned. While the per-unit cost drops significantly with high-volume production—making screen printing cost-effective for large, uniform orders—the pricing increases with colour count and complexity. It’s less practical for short runs or frequent design changes, and it often requires minimum order quantities. Bulk ordering also means you’ll need to consider storage and may be limited in the number of designs you can offer at any one time.
Print Characteristics: Appearance, Feel, Colour, & Durability
DTG printing uses water-based inks that absorb directly into the fabric, resulting in a smooth, soft-touch print that feels like part of the garment—ideal for comfortable, breathable wear. It excels at capturing fine details, making it well-suited for photorealistic artwork and intricate designs. Colours appear vibrant on light fabrics and especially rich on dark garments when pretreated, though the print can also achieve a faded, vintage-style look depending on design and curing. With proper curing on high-quality cotton, DTG prints offer solid wash durability over time.
Screen printing, in contrast, applies ink—typically plastisol—on top of the fabric in thick, opaque layers. This creates a slightly raised, tactile texture that stands out, particularly on dark garments where no pretreatment is required. It produces bold, crisp prints with high opacity and exceptional colour vibrancy, making it ideal for logos, block text, and geometric shapes. Screen prints are also highly resistant to abrasion and repeated washing, making them a go-to choice for heavy-use items like workwear and event merchandise.
Inventory & Business Model Impact
DTG printing supports a true print-on-demand model, allowing businesses to produce garments only when an order is placed. This eliminates the need to hold inventory, reducing upfront investment and risk of unsold stock. It’s particularly well-suited to small businesses, custom apparel brands, and online stores offering a large variety of designs or personalisation options. DTG makes it easy to scale design libraries without the burden of pre-printing or storage.
Efficient Prints, Smarter Growth.
Screen printing, by contrast, relies on batch production, often requiring minimum order quantities to justify setup costs. This means businesses must print and hold inventory in advance, tying up capital and increasing the risk of overstock or slow-moving items. It’s best suited to scenarios with predictable demand—such as bulk orders for corporate uniforms, promotional campaigns, or event merchandise—where the same design is repeated across many units.
Sustainability Considerations
DTG printing offers several sustainability advantages, primarily through its print-on-demand (POD) model, which helps reduce overproduction and textile waste by only printing what’s sold. Modern DTG machines—like those developed by Kornit—are designed with efficiency in mind, using advanced technology to minimise energy consumption and virtually eliminate wastewater. These systems often use water-based, biodegradable inks that are non-toxic and free from animal by-products. However, DTG does require chemical pretreatment for dark garments, which adds to the environmental footprint and requires responsible handling.
Screen printing, in comparison, tends to have a heavier environmental impact, particularly due to the use of chemical emulsions, plastisol inks, and solvents needed for screen reclaiming and cleanup. It also consumes significant water during the washing and screen preparation stages. Overproduction is another concern, as screen printing typically involves bulk runs that can lead to unsold stock and wasted resources. While large orders can minimise the environmental impact per unit, careful management of waste and ink disposal is essential to reduce harm.
Best Use Case
DTG printing is ideal for low-volume orders, typically ranging from single units up to around 50 pieces, where personalisation, design complexity, or photographic detail is a priority. It’s the go-to solution for businesses running print-on-demand models, testing new designs, or offering highly customised products—especially on 100% cotton garments. The quick turnaround and no setup requirement make it perfect for rapid prototyping or expanding product variety without holding inventory.
Use It Where It Shines.
Screen printing, on the other hand, is best suited for high-volume production runs of 100 units or more, where the same design is repeated consistently. It excels with simple, bold graphics using fewer colours (ideally under six) and is ideal for printing on synthetic or performance fabrics. Its unmatched durability makes it the preferred choice for uniforms, workwear, event merchandise, and promotional apparel requiring long-term wear and wash resistance.
DTG vs. Screen Printing: When to Choose Which Decoration Method?
Both DTG and screen printing have distinct strengths, and knowing when to use each method can help streamline your production and reduce costs.
Choose DTG printing when your design includes photorealistic images, intricate details, or a wide range of colours. It’s the ideal solution for small-batch or one-off orders, particularly for online stores offering print-on-demand apparel. DTG gives you the flexibility to print unlimited designs without setup costs, making it perfect for personalised garments, frequent design changes, and brands that don’t want to manage large inventories.
Choose screen printing for large-volume orders of simple, bold designs with limited colours. It’s the preferred method for printing solid logos, graphics, and text across uniforms, teamwear, or promotional apparel. Screen printing is highly efficient and cost-effective when producing consistent designs in bulk, especially on a wide range of fabric types, including synthetics and darks, offering durability and striking colour vibrancy that lasts.
