Screen Printing vs DTG: Which Should You Choose?
Compare screen printing and DTG printing side-by-side — costs, durability, quality, and when to choose each method
Quick Overview: Screen Printing vs DTG
Screen printing is best for bulk orders (50+ shirts) with simple designs, costs $8.99-$12.99 per shirt, lasts 50+ washes. DTG is best for small orders (1-49 shirts) with complex designs, costs $15.99-$18.99 per shirt, lasts 30-40 washes. Neither method is universally better — choose based on quantity, design, and budget.
| Feature | Screen Printing | DTG Printing |
|---|---|---|
| Best Quantity | 50+ shirts | 1-49 shirts |
| Cost Per Shirt | $8.99-$12.99 | $15.99-$18.99 |
| Setup Fees | $35-75 per color | $0 (no setup) |
| Colors | Each color adds cost | Unlimited colors |
| Durability | 50+ washes | 30-40 washes |
| Feel | Raised, thick | Soft, soaks in |
| Turnaround | 7-10 days | 3-5 days |
| Best For | Bulk, simple designs, durability | Small orders, photos, complex art |
Cost Comparison
Screen Printing Costs
- Setup: $35-75 per color (one-time)
- 50-99 shirts: $8.99-$11.99 each
- 100-499 shirts: $7.99-$9.99 each
- 500+ shirts: $6.99-$8.99 each
- Example: 100 shirts, 2 colors = $9.99/shirt + $150 setup = $1,149 total ($11.49/shirt)
DTG Costs
- Setup: $0
- 1-24 shirts: $15.99-$18.99 each
- 25-49 shirts: $12.99-$14.99 each
- Dark fabrics: Add $1-2/shirt
- Example: 10 shirts = $15.99/shirt = $159.90 total
Break-Even Point
DTG is cheaper for orders under 25-50 shirts. Screen printing becomes cheaper at 50+ shirts as setup costs spread across more units.
Durability: Which Lasts Longer?
Screen printing is more durable. Plastisol ink lasts 50+ washes without fading. DTG lasts 30-40 washes on 100% cotton.
Screen Printing Durability
- Ink sits on top of fabric (raised layer)
- 50+ washes when properly cured
- Resistant to cracking and fading
- Best for work uniforms, sports jerseys
DTG Durability
- Ink soaks into fabric fibers
- 30-40 washes on 100% cotton
- Fades faster on blends and synthetics
- Best for casual wear, event shirts
Winner: Screen printing for maximum durability.
Print Quality Comparison
Screen Printing Quality
- Vibrant, saturated solid colors
- Opaque on any fabric color
- Raised, tactile feel
- Less detail in gradients/photos
- Consistent across thousands of shirts
DTG Quality
- Photo-realistic detail
- Smooth gradients and unlimited colors
- Soft-hand feel
- Less vibrant on dark fabrics
- Slight variation between prints
Winner: Depends on design — DTG for photos, screen printing for solid colors.
When to Choose Each Method
Choose Screen Printing If:
- Ordering 50+ shirts
- Design has 1-4 solid colors
- Need maximum durability
- Want lowest cost per shirt
- Printing on dark or synthetic fabrics
Choose DTG If:
- Ordering 1-49 shirts
- Design has photos or 5+ colors
- Need fast turnaround (3-5 days)
- Want soft-hand prints
- No budget for setup fees
Still unsure? Order 1 sample with DTG to test your design, then scale to screen printing for bulk orders.
Ready to Print?
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