Three Methods, Very Different Results
Custom apparel printing has never been more accessible, but choosing the wrong method can mean wasted money, disappointing results, or garments that fade after a few washes. This guide compares the three dominant techniques — Direct-to-Garment (DTG), screen printing, and dye sublimation — so you can make the right call for your project.
Direct-to-Garment (DTG) Printing
DTG printing works like an inkjet printer for fabric. A specialised printer sprays water-based inks directly onto the garment surface, which are then heat-cured to bond with the fibres.
Best for:
- Complex, photographic, or full-colour designs
- Small order quantities (even single units)
- Designs that change between items (personalisation)
- Cotton or cotton-blend garments
Limitations:
- Not cost-effective for large bulk orders
- Results on dark garments require a white underbase, increasing cost
- Performs poorly on polyester or synthetic fabrics
- Wash durability is slightly lower than screen printing
Screen Printing
Screen printing pushes ink through a mesh screen (stencil) onto the garment. Each colour in the design requires a separate screen. It's the oldest and most established method in the apparel industry.
Best for:
- Large volume orders (typically 24+ pieces)
- Bold, graphic designs with limited colours (1–6 colours)
- Long-lasting prints that withstand frequent washing
- Most fabric types including cotton, polyester, and blends
- Specialty ink effects: metallic, glow-in-the-dark, puff, discharge
Limitations:
- High setup cost (screen creation per colour) makes low quantities expensive
- Not practical for photographic or gradient designs
- Each colour change adds cost
Dye Sublimation
Sublimation uses heat and pressure to turn special ink into a gas that permanently bonds with polyester fibres. The ink becomes part of the fabric rather than sitting on top of it.
Best for:
- All-over (edge-to-edge) printing on garments
- Sportswear, activewear, and performance apparel
- Full-colour photographic designs
- White or very light-coloured polyester garments
- Items requiring no cracking or peeling — ever
Limitations:
- Only works on polyester or polymer-coated substrates
- Cannot print on dark fabrics (ink is transparent)
- Not suitable for natural fibres like cotton
Side-by-Side Comparison
| Factor | DTG | Screen Print | Sublimation |
|---|---|---|---|
| Minimum Quantity | 1 | 12–24+ | 1 |
| Colour Complexity | Unlimited | Limited (per screen) | Unlimited |
| Best Fabric | Cotton | Most fabrics | Polyester only |
| Durability | Good | Excellent | Excellent |
| All-Over Print | No | No | Yes |
| Cost at Scale | High | Low | Medium |
Which Should You Choose?
There's no universal winner — the best method depends on your specific needs:
- Need 1–20 complex, full-colour items? → DTG is your best bet.
- Ordering 50+ shirts with a bold logo? → Screen printing will deliver the best value.
- Creating all-over polyester sportswear? → Sublimation is the only real option.
When in doubt, request samples from your printer before committing to a full production run.