T-shirt printing methods compared: screen, DTG, DTF, sublimation and embroidery

Choosing a print method is arithmetic, not taste. The right method is decided by three things: how many colours are in the design, how many pieces you are ordering, and what the fabric is made of. Here is how the five methods Chinese factories actually run compare.

Screen printing

A separate screen is made for each colour, and ink is pushed through it onto the fabric. The setup cost is fixed and paid once per colour, so the larger the run, the more sharply the per-piece share of that cost falls. The result is saturated colour and excellent wash durability beyond fifty washes. It suits designs of one to six solid colours, at quantities from 200 pieces upward. It does not suit gradients or photographs.

Direct-to-garment (DTG)

A printer sprays ink straight onto the fabric, much as an office printer does onto paper. There is no setup cost, so it works for very small runs and even single pieces. It gives unlimited colours and fine detail. It performs best on 100% cotton and holds less well on polyester. The per-piece cost stays almost flat regardless of volume, which makes it more expensive than screen printing above roughly 100 to 150 pieces.

Direct-to-film (DTF)

The design is printed onto a transparent film, dusted with adhesive powder, then transferred to the fabric with heat and pressure. Its great advantage is that it works on almost any fabric: cotton, polyester, blends, and dark colours, with no pre-treatment. Durability is good, but the hand feel sits more on the surface than screen printing, and a large solid area can crack under hard wear. Ideal for medium runs and multi-colour designs.

Sublimation

Heat turns the dye into a gas that bonds inside the polyester fibre itself. The print cannot be felt at all and never cracks, and it can cover the garment edge to edge. The decisive limit: it works only on light-coloured polyester, and not on cotton or dark fabrics. It is the standard method for sports team shirts.

Embroidery

Not printing but stitching in coloured thread. It reads as quality and is permanent through washing. It is priced by stitch count rather than area, with a one-off digitising setup fee. It suits small chest and sleeve logos, and does not suit large designs or gradients; it also adds weight and local stiffness.

A quick decision table

• One or two colours, over 300 pieces: screen printing.
• Photograph or gradient, under 100 pieces on cotton: DTG.
• Multi-colour on blended or dark fabric: DTF.
• Full-garment coverage on polyester: sublimation.
• Small logo on a corporate tee or uniform: embroidery.

Frequently asked questions

How long does a print last? Screen printing and sublimation pass fifty washes with no visible degradation. DTF holds thirty to fifty. DTG on well pre-treated cotton holds thirty to forty.

Will I pay a setup fee? Yes for screen printing and embroidery; no for DTG, DTF and sublimation.

How do I guarantee colour accuracy? By naming a reference Pantone colour in the contract and approving a printed strike-off before production starts.

We help you pick the method that fits your design and your volume, and we send an approved printed sample before production begins.