T-shirt printing has never been more popular. With the rise of online shopping and demand for personalized designs, everyone from small businesses to global brands are looking for ways to add custom prints to apparel. But with so many printing methods to choose from, how do you determine the best option for your needs?
In this blog post, we’ll compare two of the most common t-shirt printing techniques: DTF (direct-to-film) printing and traditional silkscreen printing. Read on for an in-depth look at the pros, cons, costs, and ideal applications for each method.
What is DTF Printing?
DTF printing, also known as direct-to-film printing, is a relatively new digital printing process that has grown quickly in popularity over the last decade.
How it Works:
DTF printing utilizes specialty inkjet printers and proprietary inks to print designs directly onto a pre-treated film. This printed film is then pressed onto the t-shirt using a commercial heat press, allowing the ink to permanently bond with the fabric.
Equipment Needed:
- DTF Printer: An industrial inkjet printer using specialized inks and cartridges designed specifically for printing on polymer film. These typically cost $2,000 – $30,000.
- DTF Film: The pre-treated, polyurethane adhesive film that images get printed on. Packs of film sheets cost around $1 per print.
- Heat Press: A commercial-grade heat press machine is required to transfer designs from the printed film to the garment. Expect to spend $500 – $2,000 for a quality machine.
Materials Used:
- DTF Inks: Solvent-based pigment inks that contain polymers allowing the print to bond to polyester fabrics.
- DTF Film: Polyurethane-coated film that shrinks when heat is applied, allowing the print to adhere to the garment fibers.
Advantages:
- Photographic print quality with precision detailing.
- Ability to print high-resolution photographic images and gradients.
- Wider color gamut and vibrancy than silkscreening.
- Soft hand feel after application to garment.
Disadvantages:
- Requires more equipment and setup investment.
- Higher per-print costs compared to silkscreening.
- Limited for printing extra-large runs or batches.
Now let’s look at the traditional t-shirt printing method that DTF seeks to improve upon: silkscreen printing.
What is Silkscreen Printing?
Silkscreen printing, also known as screen printing, is an analog printing process that has been used for decades to print designs on t-shirts, posters, and more.
How it Works:
Silkscreen printing uses stencils and a porous mesh “screen” to push ink directly through onto the garment. The stencil openings determine the shape of the image.
Equipment Needed:
- Silk Screens: A screen is needed for each color in the design. Screens typically cost $20-$30 each.
- Squeegee: A rubber blade used to push ink through the silkscreen. Costs $10-$20.
- Printing Press: A manual or automatic press holds the screen in place during printing. Small presses start around $300.
Materials Used:
- Plastisol Ink: The most common ink for shirt printing, plastisol needs heat to cure and bind to the fabric.
- Discharge Ink: Allows for printing on dark colored fabrics by removing dye first.
- Water-Based Ink: An eco-friendly ink alternative requiring heat curing.
Advantages:
- Classic vintage look and feel.
- Best for simple spot color designs with few blends.
- Fast and efficient for printing large orders.
- Lower per-print costs for bulk orders.
Disadvantages:
- Unable to print fine details, gradients, or photorealism.
- Requires more setup time and labor for multi-color designs.
- Screen costs add up quickly for complex designs.
Now that we’ve covered the basics, let’s compare these two methods across some key factors:
DTF vs. Silkscreen: Head-to-Head Comparison
Cost Comparison
Setup Costs
DTF has a far higher initial investment, requiring a commercial printer and heat press for $2,500+ upfront. Screen printing equipment can be purchased or DIY built at much lower costs starting around $500.
Per-Print Costs
For small runs under 50 shirts, DTF provides more affordable per-print costs around $3-$5. Silkscreening small batches drives up per-print costs due to stencil fees.
For large runs of 100+ shirts, silkscreening becomes drastically cheaper at $1-$2 per print. DTF film costs remain static regardless of order size.
Winner: DTF for small runs, Silkscreening for large bulk orders
Design Compatibility
Image Detail
DTF printing can accurately reproduce photographs, fine details, small text, and complex blends. Silkscreening lacks precision for detailed designs.
Color Range
The CMYK inkjet inks used in DTF provide a wider range of printable colors. Silkscreens are limited to the number of ink colors loaded.
Software
DTF is compatible with all image formats and files types during pre-production. Silkscreening requires converting designs to vector separations.
Winner: DTF Printing
Print Quality
Ink Vibrancy
The solvent-based DTF inks yield incredibly vibrant, saturated prints that pop off the garment. Silkscreen inks tend to be slightly more muted.
Hand Feel
DTF provides a incredibly soft finished print that retains the hand feel of the shirt. Silkscreening imparts a slight thickness and stiffness from the cured ink.
Durability
Both methods produce durable prints that can withstand dozens of washes when properly cured. DTF has a slight edge in fade and peel resistance over time.
Winner: DTF Printing
Production Speed and Scalability
Small Batches
Silkscreening’s setup time makes it less efficient than DTF for printing runs less than 12 shirts. DTF’s digital workflow allows fast single print production.
Large Batches
For orders over 100 shirts, automated silkscreen presses can print shirts in seconds. DTF’s one-at-a-time process takes exponentially longer for big runs.
Winner: DTF for small runs, Silkscreening for large runs
Material Compatibility
Fabric Types
Cotton shirts are ideal for both methods. DTF also excels at printing polyester performance apparel that traditional screen inks struggle with.
Special Fabrics
DTF's heat application process risks damage to delicate materials like wool, nylon, and spandex blends. Silkscreening is a gentler mechanical process.
Winner: Tie. Cotton = DTF = Silkscreen. Delicate fabrics favor silkscreen.
Environmental Impact
DTF printing produces some solvent waste but eliminates the water use for reclaiming screens. Overall, modern silkscreen operations tend to have greater environmental impact from ink waste and water usage.
Winner: DTF Printing
How to Choose the Right T-Shirt Printing Method
With all of these factors compared, here are some quick rules of thumb when deciding between DTF and silkscreen printing:
DTF printing is best for:
- Smaller orders under 50 shirts
- Photographic or highly detailed designs
- Polyester performance apparel
- Businesses without much startup capital
Silkscreen printing is optimal for:
- Large bulk orders of 100+ shirts
- Simple spot color designs
- Printing on delicate fabrics
- Businesses with high upfront investment funds
For many, the ideal solution is to leverage both technologies and use DTF for sampling and small batches while scaling up to silkscreening for larger production runs. Combining digital and analog allows businesses to get the best of both worlds.
Additional T-Shirt Printing Methods to Consider
Beyond DTF and silkscreening, a few other shirt printing methods are worth mentioning:
Direct-to-Garment (DTG): A digital inkjet process like DTF, but prints directly onto garments instead of transfer film. Great for fast sampling and one-offs with a softer hand than DTF.
Heat Transfer Vinyl: Cut vinyl sheets are applied with a heat press for simple, single color designs. Cost effective for low quantities although prone to peeling.
Laser Transfer Printing: Laser toners are used to print transfers for application to fabric. Provides a quick and affordable option for small runs.
With some many options to choose from, businesses should carefully weigh the tradeoffs of each method against their specific needs and goals. Testing out samples using different techniques is recommended before investing heavily in any one solution.
The Takeaway: Find the Right Fit for Your Needs
When choosing a t-shirt printing technique, there are no absolute right or wrong answers – the optimal method depends entirely on your specific goals, capabilities, and situation.
By learning the core differences between DTF printing and silkscreen printing, you can make an informed decision based on factors like:
- Your volume needs – Silkscreen handles large orders best.
- Design complexity – DTF allows photographic prints.
- Budget – Silkscreen requires lower startup costs.
- Product mix – DTF excels at polyester performance wear.
- Environmental impact – DTF is more eco-friendly.
The bottom line is understanding your own priorities and constraints. For some, fast and affordable sampling with DTF is critical. For others, silkscreen’s ability to print cheap bulk orders is most important.
Many businesses find success by leveraging both techniques – allowing them to get the quality and flexibility of DTF with the scalability of silkscreen. The right solution comes down to aligning your printing method with your goals.
With this comprehensive comparison under your belt, you can make that alignment and determine if DTF printing or silkscreening (or perhaps both) is the best fit for your next t-shirt printing project.
