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Choosing between DTF (Direct-to-Film) printing and screen printing can make or break your custom apparel project. Both methods produce quality results, but they excel in different situations—and choosing the wrong one could cost you time, money, and headaches.
Whether you are starting a t-shirt business, creating team uniforms, or producing branded merchandise, understanding the differences between DTF and screen printing will help you make the right choice for your needs. In this comprehensive guide, we will break down costs, quality, minimums, turnaround times, and when to use each method.
If you are new to custom printing, check out our DTF Printing 101 guide to learn the basics of how DTF printing works.
QUICK COMPARISON: DTF VS SCREEN PRINTING
| Factor | DTF Printing | Screen Printing |
|---|---|---|
| Minimum Order | 15 pieces (or even 1) | 50-100+ pieces |
| Setup Cost | $0 (no setup fees) | $25-75 per color |
| Color Limit | Unlimited (full CMYK) | 1-4 colors typical |
| Turnaround Time | 48-72 hours | 7-14 days |
| Best For | Small runs, detailed designs, fast projects | Large quantities, simple designs, budget focus |
| Fabrics | All fabrics (cotton, poly, blends, nylon) | Cotton best, limited on synthetics |
💡 Quick Answer: Choose DTF for orders under 100 pieces, complex designs, or fast turnaround. Choose screen printing for 100+ identical pieces with simple designs when cost-per-piece is priority.
WHAT IS SCREEN PRINTING?
Screen printing (also called silk screening) is a traditional printing method that pushes ink through a mesh screen onto fabric. Each color in your design requires a separate screen, which must be created, aligned, and printed individually.
How Screen Printing Works:
- Design is separated into individual colors
- A screen is created for each color ($25-75 per screen)
- Screens are aligned on the garment
- Ink is pushed through each screen layer by layer
- Each layer must dry before the next color is applied
This process makes screen printing extremely cost-effective for large quantities because the setup cost is spread across many pieces. However, it is expensive and slow for small runs
WHEN TO CHOOSE DTF PRINTING
DTF printing is the better choice when you need:
1. Small to Medium Quantities (1-100 Pieces)
WHY DTF WINS: No setup fees means you pay only for what you print. At Little 6 Industries, we can produce as few as 15 pieces with no price penalty. Screen printing’s setup costs make small runs prohibitively expensive.
EXAMPLE: 25 shirts with a 4-color design
– DTF: $3-5 per transfer (total: $75-125)
– Screen Printing: $150-300 setup + $4-6 per piece (total: $250-450)
2. Complex, Multi-Color Designs
WHY DTF WINS: DTF prints in full CMYK color with unlimited colors, gradients, and photo-realistic details—all at the same price. Screen printing charges $25-75 for each color screen, making complex designs expensive.
PERFECT FOR: Photographs, detailed illustrations, gradient designs, logos with many colors
3. Fast Turnaround Needed
WHY DTF WINS: DTF transfers can be produced in 48-72 hours at Little 6 Industries—sometimes same-day for local pickup in Maricopa. Screen printing typically takes 7-14 days due to screen creation, setup, and multi-layer drying time.
Need it urgently? Check out our How to Apply DTF Transfers guide to learn how to press them yourself for even faster results.
4. Multiple Design Variations
WHY DTF WINS: Need different names, numbers, or designs on each shirt? DTF makes this easy and affordable. Screen printing requires new screens for each variation, making customization expensive.
EXAMPLES: Team jerseys with individual names/numbers, personalized gifts, test designs before bulk orders
5. Printing on Difficult Fabrics
WHY DTF WINS: DTF works on cotton, polyester, blends, nylon, performance fabrics, and more. Screen printing works best on 100% cotton and struggles with synthetic materials.
PERFECT FOR: Athletic wear, moisture-wicking fabrics, poly-blend shirts, hoodies with various fabric blends
WHEN TO CHOOSE SCREEN PRINTING
Screen printing becomes the better choice when you need:
1. Large Quantities (100+ Pieces)
WHY SCREEN PRINTING WINS: Once screens are created, the per-piece cost drops significantly for large runs. The $150-300 setup cost gets spread across hundreds of pieces.
EXAMPLE: 500 identical shirts with a 2-color logo
– DTF: $3-5 per transfer (total: $1,500-2,500)
– Screen Printing: $100 setup + $2-3 per piece (total: $1,100-1,600)
2. Simple Designs (1-3 Colors)
WHY SCREEN PRINTING WINS: Simple logos with few colors minimize setup costs while maximizing the cost-per-piece advantage of screen printing on large runs.
PERFECT FOR: Company logos, basic text designs, single-color graphics
3. Repeat Orders of Same Design
WHY SCREEN PRINTING WINS: Screens can be saved and reused for future orders, eliminating setup costs for reorders. This makes screen printing economical for ongoing merchandise programs.
EXAMPLES: Company uniforms reordered annually, retail merchandise with consistent branding, recurring promotional items
4. Budget is Primary Concern (Large Orders Only)
WHY SCREEN PRINTING WINS: For orders of 100+ identical pieces with simple designs, screen printing offers the lowest cost per piece—once you absorb the setup fees.
REAL-WORLD COST COMPARISON
Here is how costs compare at different quantities:
Scenario 1: 25 Shirts, 4-Color Design
– DTF: $100-150 total ($4-6 per shirt)
– Screen Printing: $300-450 total ($12-18 per shirt)
WINNER: DTF saves $200-300
Scenario 2: 100 Shirts, 4-Color Design
– DTF: $400-600 total ($4-6 per shirt)
– Screen Printing: $500-800 total ($5-8 per shirt)
WINNER: Close tie, slight edge to DTF
Scenario 3: 500 Shirts, 2-Color Simple Logo
– DTF: $1,500-2,500 total ($3-5 per shirt)
– Screen Printing: $1,100-1,600 total ($2-3 per shirt)
WINNER: Screen printing saves $400-900