When I first started sourcing custom t-shirts, I was torn between two printing methods everyone seemed to talk about: screen printing and DTG (Direct-to-Garment). Both had strong selling points—but the price difference and when to use which weren’t always so obvious.
In this post, I’ll share what I’ve learned over the years—through client trials, failed batches, and real market testing—so you can make a smarter call for your brand.
1. How Screen Printing Works (and When It Shines)
Screen printing is the old-school champ. It uses mesh screens and ink, with each color needing a separate screen. That means there’s some setup involved, especially for multi-color designs.
But when you’re ordering in bulk, screen printing really pulls ahead. It’s reliable, fast once set up, and produces vibrant, long-lasting prints—especially on cotton-heavy fabrics. Most of our large retail buyers and promotional clients still prefer this method for simple designs.
2. DTG Printing Explained: Great for Small Runs and Complex Art
DTG is like an inkjet printer for t-shirts—it sprays water-based ink directly onto the fabric. There’s almost zero setup time and no limit on colors, which makes it ideal for photorealistic images, gradients, or artwork with lots of detail.
For smaller quantities or custom drops, we’ve found DTG to be the more flexible and less risky option. It’s also preferred by many streetwear clients or e-commerce sellers who offer limited-edition or made-to-order designs.
3. Real-World Price Comparison: Screen Printing vs DTG
Pricing is usually the big decision-maker. Here’s a side-by-side comparison of what we typically quote clients based on real production costs:
| Order Size | Screen Printing | DTG Printing |
| 50 pcs | $1.60-$6.50 | $2.00–$8.00 |
| 100 pcs | $1.20–$6.10 | $1.6–$7.60 |
| 500 pcs | $0.90–$5.60 | $1.20–$7.20 |
| 1000 pcs | $0.50–$5.20 | $0.80–$6.00 |
As you can see, DTG remains fairly constant in price, while screen printing drops fast as order size increases. That’s why we often recommend screen printing for bulk projects and DTG for test runs or online shops with varied orders.
4. Color, Fabric, and Print Complexity: What Actually Matters
If your design includes a ton of colors or gradients, screen printing gets complicated fast—not to mention expensive due to extra screens. DTG handles this effortlessly.
But DTG does have limits: it doesn’t show up well on certain poly blends or very dark fabrics without pretreatment. On the other hand, screen printing excels on nearly any material with the right ink type.
5. Turnaround Time and Setup: What to Expect
This is often overlooked, but it matters for launches. DTG jobs can be done in 1–3 days, while screen printing usually needs 5–10 days, depending on order size and number of colors.
If you’re rushing to launch or only need 30–50 shirts, DTG’s speed is a game-changer. For corporate events or big restocks, you’ll want to factor in setup time for screen printing.
6. Which Method Should You Choose?
There’s no universal “best.” It really depends on your goals:
Go with screen printing if you’re placing a large, consistent order with a simple design (like a logo tee).
Choose DTG if you need flexibility, small batches, or want to test more complex artwork before scaling.
In our own factory, we often start with DTG to test new designs with influencers or niche markets. Once a design proves itself, we shift to screen printing for larger orders to save on cost.
Final Thoughts: What’s Right for Your Brand?
If you’re a new brand or running a limited campaign, DTG can give you creative freedom without high upfront costs. But if you’re ready to go big and stick to your core design, screen printing will offer more value over time.
Still unsure? We often help clients by printing both methods for comparison. If you’re interested, just drop us a line—we’ll walk you through it.
FAQ
What’s the minimum order for DTG and screen printing?
DTG allows single-piece orders. Screen printing usually requires a minimum of 30–50 pieces due to setup costs.
How long do DTG and screen printing last?
Screen prints can last 50+ washes with minimal fading. DTG lasts around 30–40 washes before slight fading, depending on care.
Which method works better for dark-colored t-shirts?
Screen printing is more consistent on dark garments. DTG can work, but may need pretreatment and results can vary by fabric.
Can I use both methods for different SKUs?
Yes—many of our clients use DTG for custom SKUs and screen printing for their core product lines.
What’s better for on-demand or dropshipping?
DTG is more suitable for on-demand and dropshipping because of the lower setup time and print-on-demand capability.
