If you’re struggling to choose the right printing method for your shirt business to make them stand out in the market, this guide will definitely provide some ideas.Today I will give you a detailed introduction on how to choose based on the types of printing, their advantages and disadvantages, and other considerations.Choosing the right print can not only bring vibrant colors to your shirt project, but also save money for you.

Factors to Consider in Shirt Printing Methods

Complexity: DTG and heat transfer printing are suitable for shirts, while screen printing, embroidery, and dye sublimation printing are better suited for bags and hats.Of course, if you want to customize a screen-printed or embroidered shirt, Goal Sportswear as shirt supplier can do that too.

Fabric: Among all materials, cotton shirts remain the most suitable for patterned prints.Sublimation printing is more suitable for polyester fabrics.If embroidery and heat transfer printing are used, the shirt will become thicker and heavier.

Printing Purpose: Whether you want to start a shirt business or print a shirt for yourself, it is important to understand the characteristics of different shirt printing methods.DTG printing and screen printing give a casual feel, while dye sublimation printing and HTV are more suitable for sportswear, and embroidery can create an elegant and fashionable look.

Environment: The water-based ink and screen printing method do not produce toxic gases, which is beneficial to health and the environment.

The Importance of Printing on Shirts

Printed patterns can enhance the appearance of an otherwise plain shirt.Whether you want to create a casual, elegant, minimalist, or fashionable look, you can achieve it through printing technology.Whether on a fiercely competitive sports field or in a high-end banquet hall, a printed shirt can quickly attract attention.Different types of shirt printing result in different processing speeds.Therefore, if you want to get a large quantity of shirts as quickly as possible, you need to make the right choice.

Types of Printing on Clothes

1.Direct-to-garment (DTG) Printing

DTG printing technology involves applying ink directly onto the T-shirt.Unlike printing methods that use screens and transfer paper, DTG allows for printing designs directly onto T-shirts.This not only allows it to achieve photographic-quality color and pattern effects but also simplifies the operation process.It primarily uses a printer to accomplish the following steps:

Printing steps:

1. You can design patterns directly using a digital art file and then print them via a computer-connected printer；
2. Remember to spray a pretreatment solution onto the fabric to prevent smudging or discoloration during printing；
3. The shirt also needs to be ironed with a hot press to make it smooth and ensure that the subsequent pattern printing is clear；
4. Then you can place the shirt on the printing plate and feed it into the printer；
5. After printing, you dry the ink with a hot press or an air dryer to achieve a clear and vibrant printed pattern.

DTG printing allows images to be obtained directly from digital files via a computer.You can directly customize the pattern or modify the details of the pattern.Any complex, vibrant pattern is able to be freely designed, and you are not limited by the number of templates and colors.You can use DTG printing on a wide range of fabrics, such as cotton, polyester, and cotton/polyester blends.Furthermore, DTG uses water-based inks that do not contain toxic substances, making it the best environmentally friendly method for printing T-shirts.

Although DTG printers are not inexpensive, they allow you to print according to your specific needs, preventing the problem of excess T-shirt inventory.

Advantages: 

• Allows direct customization of designs via computer；
• Be compatible with complex, multi-color pattern designs；
• Suitable for printing designs on a variety of fabrics；
• Use water-based ink, which is non-toxic and environmentally friendly；
• Suitable for mass production of shirts.

Disadvantages:

• Printing effect on polyester shirts is average；
• The printed pattern is not as washable or sun-resistant as screen-printed patterns；
• DTG printers are relatively expensive.

2.Screen Printing

Screen printing is also known as silkscreen printing.It transfers ink onto the shirt through a mesh stencil and squeegee.However, each color printing requires a separate template.

Printing steps: 

1. First, print a digital file on a transparent acetate film as a template；
2. Then you need to confirm the number of grids and select the screen based on the design pattern.The higher the level of detail required for a pattern, the greater the number of mesh points needed；
3. Next, apply a light-reactive emulsion layer (such as Diazo, SBQ-based, or Dual-cure emulsions) onto the mesh screen.Different emulsions will vary in their performance details, price, and curing time；
4. You place a transparent acetate film on a screen and cure the emulsion by exposing it to light.Different colors require multiple screens；
5. Through exposure, the screen coated with photosensitive emulsion hardens, while the unexposed areas remain soft.After rinsing, holes filled with the designed pattern can be formed；
6. The ink is printed through a screen to form the pattern；
7. Arrange the screen, printing materials, and printing plates from top to bottom;
8. Then, after adding colored ink to the screen, use a squeegee to spread it evenly.The ink will pass through the template and form a design pattern on the shirt;
9. After printing is complete, use a special washing solution to remove the emulsion.The cleaned screen mesh serves as a new template for reuse；
10. Finally, cure the ink pattern using a dryer.

Screen printing is also a very popular printing method used in the clothing industry.However, the time required to prepare the templates and screens for screen printing is too long, which makes it much less cost-effective.If you want to print a large quantity of T-shirts, screen printing is still your best option.

Advantages: 

• Capable of printing bright and simple designs;
• The printed patterns are very durable;
• Suitable for large-volume T-shirt orders;
• Suitable for printing on a variety of fabrics.

Disadvantages: 

• Not suitable for rich colors and patterns;
• A significant amount of time was spent creating templates;
• Not suitable for small-scale shirt printing;
• Require a lot of ink and materials, which may lead to waste.

3.Dye Sublimation Printing

Sublimation printing involves heating ink to directly sublimate it into gas, thus achieving fusion with the fabric.This printing method is durable and does not easily fade.

Printing steps: 

1. Create design patterns directly from digital image files;
2. Print a reversed pattern on transfer paper;
3. Heat press machine transfers patterns onto heat-transfer paper.

Dye sublimation printing is ideal for printing on synthetic fabrics.The heating method allows the ink to fuse well with the synthetic fabric, resulting in durable printed T-shirts. However, sublimation printing and cotton fabrics do not have good physical compatibility.

Advantages: 

• Provide a smooth and vibrant texture;
• Printed T-shirts are resistant to fading and peeling;
• Enable full-coverage printing on T-shirts.

Disadvantages: 

• For cotton and dark shirts, dye sublimation printing requires specialized vinyl materials;
• The entire dye sublimation process requires expensive materials and machinery.

4.Heat Transfer Vinyl (HTV)

HTV printing involves cutting out designs from vinyl sheets, attaching them to transfer paper, and then applying heat and pressure using a heat press. The letters and numbers you often see on sportswear are made using HTV printing. 

Printing steps:

1. Cut out the pattern yourself or use digital cutting;
2. HTV cutting machine precisely cuts out patterns;
3. Weeding removes excess material;
4. Pattern printing is performed using a heat press machine.

Unlike heat sublimation printing, HTV printing does not require the use of ink. It requires the use of a cutting machine to cut out the pattern on the vinyl and heat the vinyl sheet against the shirt, which enables the brightly colored pattern to be bonded to the shirt.

Advantages: 

• HTV can print on dark-colored clothing fabrics;
• Shirts printed using HTV technology can achieve rich colors;
• The operation method is simple.

Disadvantages: 

• Require time to cut the vinyl;
• Complex pattern designs are not supported;
• Not suitable for mass production of shirts.

5.Plastisol Heat Transfer

Plastisol heat transfer involves printing a design onto a plastic transfer sheet and then transferring the ink to the shirt.This method is simpler than screen printing. Patterns for jerseys and work uniforms often use this method.

Printing steps:

1. Use desiccant to remove moisture from the transfer paper to prevent the pattern from smudging;
2. Place the transfer paper on the screen and apply ink to it;
3. Pattern transfer using a hot press;

Plastisol heat transfer can produce glossy and textured print effects.However, since each T-shirt requires a separate transfer paper, this method is not suitable for large-volume T-shirt orders.If your order volume is small, you can store the gel plastic transfer paper before printing and then heat the transfer paper directly during the printing process.

Advantages：

• The transfer paper allows you to reuse it for printing patterns；
• Create high-quality, textured pattern printing;
• Suitable for small-batch shirt customization;

Disadvantages:

• The production process will take more time;
• Transferring paper and screens will incur additional costs.

6.Embroidery

Embroidery is the process of sewing patterns onto a shirt using an embroidery machine.The patterns printed using embroidery machines are not only durable but also give a luxurious look.

Printing steps:

1. Prepare digital embroidery files;
2. The 3D embroidery effect is created by sewing with a sewing machine.

Logos, names, or small icon designs on shirts can be created using embroidery. Compared to other shirt printing methods, embroidery is more time-consuming and expensive. Furthermore, you can’t design very complex patterns with it.

Advantages: 

• Dense stitching, very durable;
• Embroidered shirts are more elegant;
• It is more environmentally friendly than other printing methods of T-shirts.

Disadvantages: 

• Higher cost compared to DTG and screen printing;
• There are limitations on the line colors that can be selected.

7.Discharge Printing

Unlike ink-based printing, discharge printing creates patterns by removing the original color from the fabric.If you apply fading ink to a shirt, it will fade and leave a lighter-colored pattern.

Advantages:

• Discharge printing does not produce a plastic feel, and the shirt is very soft;
• No need to worry about the printed pattern cracking;
• It’s perfect for printing on dark shirts.

Disadvantages: 

• Difficulty in controlling the shades of the pattern colors;
• It can severely damage the fabric. It is not suitable for synthetic fabrics；
• Because fading ink produces a pungent odor.

How to Choose the Method of Printing on T-shirts

Create Printed Shirts with Goal Sportswear

The above describes seven types of printing on garments.Each of them has its own advantages and disadvantages.You need to consider not only the fabric and intended use, but also cost calculations, and so on.Goal Sportswear can help you solve these problems.We will provide the best shirt printing method based on your needs, truly meeting your core requirements.In addition, Goal Sportswear— sportswear factory, excels in sublimation printing.We will use high-quality fabrics and sublimation inks to print vibrant and detailed patterns.It is smooth, washable, and does not feel heavy.Whether you need custom orders or urgent production, our advanced equipment and experienced technicians can complete complex and professional shirt printing designs.

FAQ

Which printing method is the most durable?

Screen printing, embroidery, and sublimation printing patterns can withstand long periods of washing and sun exposure without easily fading or cracking. If you value print stability, these three shirt printing methods are worth considering.

What’s the cheapest shirt printing method?

If you just want to experience DIY shirt printing at home, heat transfer paper is suitable. It won’t take too much time or cost. However, if you are a brand owner or shirt manufacturer looking for large-volume printing, screen printing is the cheapest shirt printing method.

Which is better, DTF or DTG?

DTF is more durable. Unless subjected to prolonged hot water washing, DTF-printed shirts can maintain their new look for a long time.