Types of Shirt Printing: Picking the Best Method for Your Brand

Picking the best method for printing t-shirts is crucial when starting a custom t-shirt business. 

The ideal printing method for your business depends on the fabric you’re using, the number of t-shirts you want to print, the designs you have in mind, the level of detail you expect, and the amount of time and money you’re willing to invest.

In this blog, we’re exploring the types of t-shirt printing available to personalize your favorite tees, covering all the bases to help you make an informed decision. From the fabric types to the design options available for each method—we’ve got it all.

Ready? Let’s go for a ride!

7 most popular types of shirt printing

To better understand each t-shirt printing method, let’s examine fabric compatibility, design options, and the scenarios where each method works best.

1. Screen printing

Screen printing, also known as silkscreen printing, is one of the oldest and most efficient methods for t-shirt printing. This technique produces vivid and durable designs at a cost-effective rate.

The screen printing process involves a stencil, a mesh screen, and a squeegee or straight blade to transfer the design to the t-shirt. First, a stencil of the design is created and placed on a mesh screen. Ink is then poured over the stencil and pressed through the mesh onto the fabric using a squeegee or blade. The excess ink is then wiped off, and the t-shirt is left to dry.

Materials

Screen printing works best on natural fabrics such as cotton, silk, and wool, allowing for optimal ink absorption and adhesion and producing vibrant and durable prints.

While it’s possible to use natural and synthetic blends, the quality and longevity of the print may vary. Purely synthetic fabrics like polyester, spandex, and lycra are generally not recommended for screen printing due to their smooth, non-porous surfaces, which can hinder ink adhesion and lead to less durable results.

Designs

Screen printing is renowned for producing high-quality, long-lasting prints that maintain vibrancy through repeated washes.

This method excels with bold and simple designs, making it a preferred choice for logos, text, and other graphic elements that require solid areas of color. However, the stencil and mesh screen’s limitations make it less suitable for intricate or highly detailed designs.

The process typically accommodates a limited number of colors, as each color requires a separate screen and pass, which can increase the complexity and cost. This characteristic makes screen printing ideal for straightforward, impactful designs with few colors, ensuring the final product remains cost-effective and visually striking.

Best for

Screen printing is particularly well-suited for one-color designs and mass production of the same design.

Screen printing is fast and wallet-friendly for large quantities, making it ideal for bulk orders. It’s excellent for producing uniforms, promotional items, or event merchandise. However, it’s not suited for designs that demand a lot of detail and multiple colors.

2. Direct-to-garment printing

Though relatively new, direct-to-garment (DTG) printing is one of the most popular t-shirt printing techniques on the market.

DTG printing can be likened to printing on paper—it prints directly on the fabric. The process starts with applying a pre-treatment solution to help the ink adhere to the fabric. Then, the garment is placed on a platen and inserted into the printer, where the design is applied in just a few minutes. Finally, the ink is cured to ensure the print’s durability.

Materials

DTG printing provides the best results on 100% cotton shirts due to cotton’s excellent ink absorption properties. While cotton blends are also compatible, they may not achieve the same vibrancy as pure cotton.

DTG printing is generally not recommended for synthetic fabrics, as the ink does not adhere well, leading to subpar results.

Designs

DTG printing excels in producing intricate designs with an unlimited color palette, offering precise and accurate results. This method is ideal for detailed artwork, photographs, and designs with complex color gradients and nuances.

Printing directly onto the fabric without separate screens allows for high-resolution, detailed prints. However, achieving high-quality prints on darker fabrics can be challenging due to the thin nature of the ink, so applying a white underbase is recommended to maintain the design’s true colors.

Best for

DTG printing is particularly well suited for smaller businesses and individuals who focus on custom t-shirts or apparel but don’t need large orders.

This method allows for one-off prints, enabling businesses to test different designs and offer products on demand without maintaining extensive inventory. It’s ideal for brands that prioritize flexibility and customization, making it easy to fulfill unique customer requests and produce limited-edition items.

Learn more: DTG vs. Screen Printing

3. Direct-to-film printing

Direct-to-film (DTF) printing is one of the most versatile t-shirt printing methods. Unlike other techniques, DTF printing uses a film to transfer the design onto the t-shirt, and it’s compatible with various fabric types.

DTF printing involves printing the design on a PET film using water-based inks and a powder that helps transfer the design. Before applying the print, the fabric must be dehumidified and pre-flattened. After transferring the design at an average temperature of 165°C, the film is cold peeled, and the fabric undergoes a second flattening to ensure the design’s durability.

Materials

A major advantage of DTF printing is its exceptional versatility. This method can be used on a wide variety of fabrics, including cotton, polyester, fleece, nylon, and blended fabrics, making it one of the most flexible t-shirt printing techniques available.

This versatile compatibility allows for a broad range of applications and opens up opportunities for printing on different types of apparel. Dehumidifying and pre-flattening the fabric before printing ensures optimal adhesion and print quality, regardless of the fabric type.

Designs

DTF printing is ideal for creating elaborate designs with unlimited colors and intricate details.

Compared to DTG printing, DTF produces thicker prints, which can add a distinct texture and feel to the garment. The accurate and vivid design outcomes make DTF printing perfect for complex artwork and designs that require a rich color palette and fine detail.

Best for

DTF printing is particularly well-suited for producing multiple t-shirts with the same design, making it an excellent choice for bulk orders. One film can be used to print on multiple shirts, improving efficiency and reducing costs.

This method is versatile enough to work on various types of fabric, making it ideal for businesses that offer a wide range of apparel products.

Learn more:

DTF vs. DTG Printing

DTF vs. Sublimation Printing

DTF vs. Screen Printing

4. Heat transfer vinyl printing

Heat transfer vinyl (HTV) printing is commonly used for printing player numbers, names, and logos on sports team shirts or jerseys. This method involves cutting designs on colored heat transfer vinyl with a machine, then transferring them onto the t-shirt using a heat press.

HTV printing, also known as iron-on printing, uses vinyl plastic-based sheets. One side of the sheet is colored with removable tape and cut into shapes, while the other side is coated with an adhesive activated by heat.

Materials

HTV printing is particularly effective for fabrics that can withstand high temperatures, making it an excellent choice for athletic wear and team jerseys.

HTV printing is ideal for fabrics like cotton, polyester, and poly-cotton blends, which are durable and can endure the heat required for the transfer process.

Designs

HTV printing allows you to choose from a variety of vibrant colors, resulting in high-quality and eye-catching prints. 

The rigidity of the vinyl can make the fabric less flexible and comfortable, so HTV printing is best suited for smaller prints, such as names, numbers, and logos, rather than large designs.

Valuable read: A Step-by-Step T-Shirt Design and Logo Placement Guide

Best for

HTV printing is best for precise, durable designs, such as sports team apparel. However, the process can be time-consuming due to the meticulous vinyl cutting and weeding, which slows down production.

HTV printing isn’t suitable for large-scale production due to the manual effort involved. Instead, it excels in small-scale projects where customization and durability are paramount, such as individual team jerseys, personalized apparel, and promotional items.

5. Sublimation printing

Sublimation printing, also known as dye sublimation or digital sublimation, is an industry staple for creating stunning custom apparel. 

First, the design is printed onto heat transfer paper. Heat is then applied to the transfer paper, causing the ink to penetrate the fabric. This special liquid dye changes the fabric’s color and creates a smooth, lightweight feel, resulting in vibrant and durable prints. After printing, the fabric is cut according to garment patterns and sewn together to ensure the design aligns correctly across different parts of the garment.

Materials

Sublimation printing is designed explicitly for synthetic fabrics, with polyester being the most suitable material. This technique is incompatible with cotton t-shirts because the dye requires synthetic fibers to adhere correctly.

Polyester’s unique structure effectively bonds the dye, producing long-lasting prints. While other synthetic fabrics can also be used, polyester ensures the best color intensity and durability results.

Designs

Sublimation printing excels at producing detailed and vivid designs that cover the entire garment. The printing process changes the fabric’s color and creates a smooth feel.

Best for

Sublimation printing is ideal for creating all-over print t-shirts and other apparel items, where the design spans from seam to seam.

This method is suitable for on-demand production, letting you create original designs without acquiring inventory. However, printing each design on transfer paper and cutting and sewing the fabric makes sublimation time-consuming and less cost-effective for bulk orders. It’s better suited for small-scale production runs, custom pieces, and niche markets where high-quality, detailed prints are essential.

6. Airbrushing

If you enjoy creative experiments, airbrushing can be an excellent option. While it requires significant technical mastery, you’ll get original results, reminiscent of graffiti.

The process is simple—all you need is an airbrush gun, paint, and a stencil to get started.

Materials

Airbrushing can be used on various fabrics, but the type of paint you choose will significantly impact the results. Fabric paints with dyes and binding agents are designed for natural fibers such as cotton.

Acrylic paints, on the other hand, can be used on both natural and synthetic materials, offering more options. However, perform a test run before committing to a full project, as some fabrics and colors may not hold the paint well or may react unpredictably to the airbrushing process.

Designs

Airbrushing allows for unparalleled creativity, enabling artists to experiment with colors, gradients, and effects to create truly unique designs.

The technique is reminiscent of graffiti art, with its bold strokes and dynamic visuals. However, airbrushing has its limitations—it doesn’t support intricate detail well, and the resulting designs tend not to last long. The ink can wear off over time, particularly with repeated washing.

Despite these drawbacks, airbrushing is an easy and inexpensive method that offers complete artistic freedom, making it ideal for one-of-a-kind pieces and experimental designs.

Best for

Airbrushing is best suited for small, personalized projects where creativity and uniqueness are paramount. The manual nature of the process makes it unsuitable for large orders, as it’s time-consuming, labor-intensive, and hard to replicate.

Additionally, the low durability of airbrushed designs means they’re not ideal for items that will be frequently used and washed. It’s perfect for individual artists, hobbyists, and small businesses that want to offer custom, one-of-a-kind garments.

7. Plastisol transfers

Plastisol transfers fall under the screen printing category but involve an additional step—the design is first applied to printing paper.

The process begins similarly to screen printing, using a stencil and a mesh screen. However, instead of printing directly onto the garment, the design is digitally printed on plastisol transfer paper. This transfer paper is then used to print the design onto a t-shirt using a heat press.

This extra step makes plastisol transfers especially suitable for demonstrations, allowing you to prepare in advance. You can create the transfer paper once and then quickly and easily print the design onto a garment whenever needed. 

Source: ScreenPrinting.com

Materials

Plastisol transfers are particularly suitable for tougher fabrics, like fleece, which can withstand the heat press without damage. While it can be used on a variety of different fabrics, the best results are typically seen on more robust materials that can handle pressure and heat.

This makes plastisol transfers a versatile option for garments intended for heavy use or frequent washing, ensuring that the design remains intact.

Designs

Plastisol transfers offer durable prints with a quality comparable to traditional screen printing. This method is great for creating detailed designs, as printing on plastisol transfer paper allows for precise control over design elements and colors.

Once transferred to the garment, the prints are long-lasting and can endure multiple washes without significant fading or cracking. This technique is ideal for designs that require bold colors and sharp lines, providing a reliable solution for creating high-quality, resilient prints.

Best for

Plastisol transfers are ideal for live printing or printing in front of an audience, for example, at events or in custom t-shirt booths. The ability to prepare the transfer paper in advance and apply the design quickly on-site makes this method highly practical for interactive or on-demand printing.

However, the additional steps involved in creating and using the transfer paper make plastisol transfers less suitable for large-scale operations. The process can be time-consuming and requires a high level of expertise, which can slow down production.

Side-by-side comparison

Now that we understand the ins and outs of each printing method, let’s have a look at how they stack up side by side.

Valuable read: 8 Best Quality T-Shirts for Printing

Bring your ideas to life

Understanding the basics of each printing method is crucial when starting a t-shirt business. This involves examining fabric compatibility, design quality, upfront investments, and long-term costs.

Partnering with a print-on-demand provider like Printful might be a solid move, especially if you aim to sell custom t-shirts online with minimal initial investment. This fulfillment method allows you to start selling with almost zero initial capital. Printful handles printing, packing, and shipping, so you don’t have to worry about production or logistics.

Time to sell some tees! What’s holding you back?

Read next: 56 T-Shirt Design Ideas That Are Seriously Next-Level

FAQs

What type of t-shirt printing lasts the longest?

When it comes to print longevity, the two industry juggernauts are screen printing and sublimation. The choice really comes down to the fabric you want to print on, as screen printing is meant for natural fabrics, while sublimation supports synthetic fabrics.

Is DTG or DTF better?

DTF is better for detailed, colorful designs on synthetic materials like polyester, nylon, and fleece. But, due to breathability issues, it’s less suitable for large designs.

DTG is ideal for cotton garments and natural materials. It handles larger designs well and is great for simple graphics, text, and logos. While it supports colorful images, the clarity might not match DTF.