Key Questions to Ask

• How many shirts do you need? (Quantity affects method choice)
• What’s your budget? (Per-piece cost varies dramatically)
• What fabric are you printing on? (Cotton, polyester, blends?)
• How complex is your design? (Full color photos vs simple logos)
• How durable must it be? (Occasional wear vs daily workwear)
• What’s your timeline? (Rush orders vs planned production)

Step 1: Design is printed onto PET film using specialized CMYK+White ink

Step 2: Hot-melt adhesive powder is applied to wet ink

Step 3: Film goes through curing oven (powder melts and bonds to ink)

Step 4: Transfer is applied to garment using heat press (305-315°F for 15 seconds)

Step 5: Film peels away (hot or cold peel depending on film type), design remains on fabric

• Works on any fabric: Cotton, polyester, blends, nylon, even leather
• Full-color capability: Photos, gradients, unlimited colors
• No minimums: Economical for 1 shirt or 1,000 shirts
• Soft hand feel: Thin, flexible, breathable
• Excellent durability: 40+ washes when applied correctly
• Works on dark fabrics: White underbase prints under colors
• Fast turnaround: No screens to make, no setup time
• Complex designs welcome: Fine details, small text, photorealistic images

• Not truly “no-feel”: You can feel the transfer (though it’s thin)
• Heat-sensitive fabrics: Can’t press nylon at high temps (workaround: lower temp + longer time)
• Per-piece cost: Higher than screen printing for very large runs (500+ same design)
• Not vintage look: DTF looks modern and crisp, not distressed

Typical pricing at Little 6:

• Small design (5×5″): $5-8 per transfer
• Medium design (8×10″): $8-12 per transfer
• Large design (11×15″): $12-18 per transfer

Add garment cost (blank shirt/hoodie) if we’re providing it. Or bring your own garments and we’ll just charge for transfers + pressing.

Step 1: Design is separated into individual colors

Step 2: A screen is made for each color (photo emulsion process)

Step 3: Shirt is loaded onto print platen

Step 4: Ink is pushed through screen using squeegee (one color at a time)

Step 5: Each color is flashed (partially cured) before next color

Step 6: Final curing in conveyor dryer (typically 320°F for cotton)

• Lowest per-piece cost for large runs: Unbeatable economics at 500+ pieces
• Most durable: Ink becomes part of fabric, lasts 50+ washes
• Vibrant colors: Plastisol inks produce bold, opaque colors
• Special effects possible: Puff ink, metallic, glow-in-dark, discharge printing
• Industry standard: Proven technology with consistent results
• True “no-feel” possible: Water-based inks soak into fabric
• Pantone matching: Exact color matching available

• High setup costs: Screen fees ($15-50 per color) make small runs expensive
• Color limitations: Each color adds cost. Full-color photos are impractical.
• Minimum quantities: Most shops require 24-50 piece minimums
• Design restrictions: Fine details can be challenging
• Longer turnaround: Screen making adds days to production
• Not economical for multiple designs: Each design needs new screens
• Dark garments require extra steps: Underbase white, more flash curing

Typical screen printing pricing:

• Setup: $15-50 per screen (one-time per design/color)
• Per piece (100 shirts, 1-color): $4-6
• Per piece (100 shirts, 4-color): $8-12
• Per piece (500+ shirts, 1-color): $2-3

Note: We don’t offer screen printing at Little 6. We focus on DTF. However, for orders over 500 pieces of the same simple design, we’ll refer you to a screen printer.

Step 1: Design is digitized (converted to stitch file)

Step 2: Garment is hooped (held taut in embroidery hoop)

Step 3: Backing/stabilizer is placed behind fabric (prevents puckering)

Step 4: Machine stitches design following digitized pattern

Step 5: Excess backing is trimmed, loose threads are cut

• Most durable: Thread won’t crack, peel, or fade. Lasts life of garment.
• Premium appearance: Textured, dimensional, professional
• Perceived value: Customers see embroidery as higher quality
• Versatile applications: Works on shirts, hats, bags, jackets, towels
• Doesn’t fade: Thread color is permanent
• Works on any fabric: Cotton, polyester, nylon, leather, denim
• Corporate standard: Expected for business casual/professional wear

• Design restrictions: Small text (under 0.25″) doesn’t embroider well
• Not for photos: Can’t reproduce photorealistic images
• Higher per-piece cost: More expensive than printing methods
• Digitizing fee: One-time setup ($25-75) to create stitch file
• Stitch count matters: Complex designs with high stitch counts cost more
• Limited color blending: No gradients or color transitions
• Can be stiff: Dense embroidery can make fabric rigid
• Not ideal for large designs: Works best for logos under 4-5 inches

Typical embroidery pricing:

• Digitizing fee: $25-75 (one-time per design)
• Left chest logo (typical): $6-10 per piece
• Hat embroidery: $8-12 per hat
• Large back design: $15-25+ per piece

Note: We don’t offer embroidery at Little 6. We specialize in DTF printing. For embroidery needs, we can refer you to local embroiderers.

Step 1: Design is cut from vinyl sheet using vinyl cutter or craft cutter

Step 2: Excess vinyl is “weeded” away (removed from carrier sheet)

Step 3: Design is positioned on garment

Step 4: Heat press applies heat and pressure (typically 305°F for 10-15 seconds)

Step 5: Carrier sheet peels away (hot or cold depending on vinyl type)

• DIY-friendly: Home crafters can do this with a Cricut
• Low startup cost: Minimal equipment investment
• No minimums: Make one shirt at a time
• Quick turnaround: Cut and press in minutes
• Specialty finishes: Glitter, metallic, holographic, flock (fuzzy texture)
• Good durability: 25-50 washes when applied correctly
• Layerable: Multiple colors can be layered

• Single-color only: Each piece of vinyl is one solid color
• No photos or gradients: Only solid colors and shapes
• Labor-intensive: Weeding and layering takes time
• Design limitations: Thin lines and small details are difficult
• Thick hand feel: Vinyl sits on top of fabric, doesn’t integrate
• Not cost-effective at scale: Per-piece cost doesn’t drop with quantity
• Can crack or peel: Especially if applied incorrectly or washed hot
• Complex designs are tedious: Multi-layer designs require precise alignment

Typical HTV pricing:

• Simple name/number: $5-10 per piece
• Small logo (single color): $8-12
• Multi-color design: $12-20+ (due to labor)

Note: We don’t offer traditional HTV services at Little 6. For simple, solid-color designs, DTF is more cost-effective and produces better results.

Step 1: Design is printed onto special sublimation paper using sublimation ink

Step 2: Paper is placed face-down on polyester fabric

Step 3: Heat press applies high heat (400°F) and pressure for 45-60 seconds

Step 4: Dye sublimates (turns to gas) and bonds with polyester molecules

Step 5: Paper is removed, design is permanently embedded in fabric

• True “no-feel”: Design is IN the fabric, not ON it
• Never cracks or peels: Can’t wash off (it’s part of the fiber)
• Unlimited colors: Full-color photos, gradients, no color upcharge
• Vibrant colors: Especially bright on white polyester
• Breathable: Doesn’t add a layer, doesn’t block airflow
• Full-coverage designs: Can print edge-to-edge (all-over prints)
• Permanent: Color won’t fade over time

• Polyester ONLY: Requires minimum 65% polyester (100% polyester ideal)
• Doesn’t work on cotton: Dye won’t bond to natural fibers
• Light colors only: Works best on white. Colors look faded on dark fabrics.
• Can’t print white: No white ink in sublimation (fabric color shows through)
• Polyester requirement limits options: Not everyone likes polyester feel
• Colors can shift: Sublimation ink looks different printed vs pressed

Typical sublimation pricing:

• Standard size print: $8-15 per piece
• All-over print: $20-35 per piece
• No color upcharges (unlimited colors included)

Note: We don’t offer sublimation at Little 6. For polyester garments, we recommend DTF instead. DTF works on cotton AND polyester, giving you more fabric options.

1-50 pieces: DTF or HTV (if simple)

50-500 pieces: DTF (full color) or Screen Printing (simple designs)

500+ pieces: Screen Printing wins on cost

Full-color photos: DTF or Sublimation (polyester only)

1-4 solid colors: Screen Printing or DTF

Simple text/numbers: HTV or DTF

Small logo (left chest): Embroidery or DTF

100% Cotton: DTF, Screen Printing, HTV, Embroidery

100% Polyester: DTF, Sublimation, Embroidery

Cotton/Poly Blends: DTF, Screen Printing, HTV, Embroidery

Nylon (jackets): DTF (low temp), Embroidery

Tightest budget (bulk orders): Screen Printing

Moderate budget (small runs): DTF or HTV

Premium budget: Embroidery

Event giveaways: DTF or Screen Printing

Corporate uniforms: Embroidery or Screen Printing

Sports jerseys: HTV (numbers) + Screen Print or DTF (design)

Athletic wear (polyester): Sublimation or DTF

Fashion/retail: DTF or Screen Printing

Workwear/uniforms: Screen Printing or Embroidery

I’ve been honest in this guide. Screen printing beats DTF for huge runs. Embroidery beats DTF for premium corporate logos. Sublimation beats DTF if you only print on white polyester.

However, DTF is the most versatile method. Here’s why we chose it:

No Minimums Philosophy

We don’t believe you should have to order 50 shirts to get custom apparel. DTF makes one-offs economical. Therefore, we can serve small businesses, individuals, and anyone who doesn’t need bulk.

Works on Everything

Cotton? Yes. Polyester? Yes. Blends? Yes. Dark colors? Yes. Light colors? Yes. We don’t have to turn customers away because they brought the “wrong” fabric.

Full-Color Capability

Photos, gradients, complex artwork—DTF handles it all. Moreover, there’s no color upcharge. Six colors costs the same as one color.

Fast Turnaround

No screens to burn. No embroidery digitizing. Print, powder, press, done. Consequently, we can deliver same-day or next-day on many orders.

Multiple Designs Per Order

Need 10 different designs for 10 different people? No problem. Screen printing would require 10 sets of screens. DTF just requires 10 prints.

Contact Little 6 Industries

📞 (520) 705-4026

📧 matt@little6llc.com

🌐 little6llc.com | transfers42.com

Located in Maricopa, Arizona
Serving businesses across Arizona and nationwide

DTF Transfers • No Minimums • Fast Turnaround

We specialize in DTF printing for custom apparel. One piece or 1,000 pieces. Full-color designs. Any fabric. Rush orders welcome (no rush fees).