DTG vs Screen Printing

Walk into any custom t-shirt shop, and you’ll hear two printing methods debated more fiercely than sports teams: DTG or screen printing. Both promise bold colors and lasting designs, but the way they bring artwork to life couldn’t be more different. So, how do you know which one’s really worth your fabric?

DTG Printing

Direct-to-Garment (DTG) printing is a digital technique that prints designs straight onto fabric using specialized inkjet technology. Before printing, the garment is pre-treated with a bonding solution that helps the ink adhere to the fibers. Once printed, the fabric is heat-cured, locking in the colors and producing a smooth, soft finish that becomes part of the garment rather than sitting on top of it.

Because DTG works much like a paper printer, but for clothing, it’s perfect for detailed artwork, gradients, and full-color images. There’s no need for screens or plates, which makes it fast and cost-effective for small orders or custom, print-on-demand items.

Pros of DTG Printing

Produces vibrant, photorealistic designs with smooth gradients and intricate details.
Ideal for one-off pieces or small batches without setup costs.
Since it’s a digital process, designs can go straight from file to fabric in minutes.
The ink absorbs into the fabric, resulting in a smooth texture rather than a heavy layer on top.
Products can be printed only when ordered, reducing inventory waste.

Cons of DTG Printing

Not the most economical choice for bulk production compared to screen printing.
Each garment is printed individually, which can limit output for large orders.
Works best on 100% cotton or high-cotton blends; synthetic fabrics may not hold ink as effectively.
Professional DTG printers and maintenance can be expensive for small-scale setups.

Screen Printing

Screen printing is a classic printing technique that’s been a cornerstone of apparel decoration for decades. It works by pressing layers of ink through a fine mesh stencil (or screen) onto fabric.

Each color in a design requires its own screen, which means multi-colored artwork involves several passes of ink. The result is a bold, vibrant print with a slightly raised texture that you can feel,

While the setup takes time, the payoff comes in speed and efficiency once printing begins. For large production runs, screen printing becomes extremely cost-effective, making it the go-to choice for bulk orders of t-shirts, hoodies, and promotional products.

Pros of Screen Printing

The more you print, the lower the cost per item, making it ideal for large batches.
Screen-printed designs hold up well against frequent washing and heavy wear.
The thick ink layer produces bold, saturated tones that pop on fabric.
Effective on cotton, blends, polyester, and even non-fabric surfaces like posters or bags.
Can use unique inks like metallic, puff, or glow-in-the-dark for creative finishes.

Cons of Screen Printing

Each color requires a separate screen, increasing prep time and cost for small orders.
Not ideal for designs with gradients, fine details, or a large number of colors.
Equipment, screens, and inks make small runs more expensive.
Traditional screen printing uses more water and chemicals compared to digital methods.

The Key Differences Between DTG Printing and Screen Printing

Choosing between DTG printing and screen printing depends on what matters most for your business. While both methods can produce high-quality results, they differ in how they achieve them and what kinds of projects they’re best suited for.

Print Quality and Durability

DTG printing stands out for its ability to capture intricate, high-resolution details. It’s the preferred option for complex artwork, photographic prints, and designs featuring gradients or subtle color transitions. Because the ink is absorbed into the fabric fibers, DTG prints feel soft and smooth to the touch.

Screen printing, however, wins when it comes to durability. Its thicker ink layers sit on top of the fabric, creating vibrant, bold colors that hold up exceptionally well after repeated washes. That’s why screen printing remains the top choice for uniforms, athletic wear, and promotional garments that need to last.

Design Complexity and Color Range

When it comes to creative flexibility, DTG takes the lead. A digital printer can reproduce any design, no matter how many colors or how detailed it is, without increasing setup time or cost. This makes DTG ideal for brands offering frequent design changes, customized products, or one-off prints.

Screen printing, in contrast, works best with simpler graphics, bold typography, and limited color palettes. Since each color requires its own screen, detailed or multi-colored designs take more time and money to produce. Most providers also cap color usage, typically up to nine shades per design.

Color Vibrancy

Both methods deliver striking colors, but in different ways. Screen printing uses thick, opaque inks that create rich, saturated tones — especially effective on dark fabrics or high-contrast designs.

DTG achieves vibrancy through precision and color blending. Its water-based inks soak into the fibers, allowing for a natural look and excellent accuracy in gradient-heavy or photo-realistic artwork.

Fabric Compatibility

DTG printing performs best on 100% cotton and cotton-rich blends, where inks can properly bond with the fibers. It can also print on dark fabrics using a white underbase layer applied during the pre-treatment process.

Screen printing, however, is more versatile across materials. It works well on cotton, polyester, nylon, and other synthetic fabrics, making it a great fit for sportswear or performance gear. The thicker ink layers also make screen prints stand out on both light and dark materials without extra preparation.

Sustainability and Environmental Impact

DTG printing offers a more sustainable model, particularly in the era of print-on-demand production. Since items are printed only when ordered, there’s minimal waste and no overstock. Modern DTG printers, like those developed by Kornit, also use water-based, vegan inks and energy-efficient systems that drastically reduce water and chemical use.

Screen printing, while reliable, tends to have a larger environmental footprint. The process involves more water, chemical solvents, and leftover ink during screen cleanup. Bulk production also increases the risk of unsold inventory.

Order Size and Production Speed

DTG printing is perfect for small runs or single-item orders. There’s virtually no setup time, so designs can go straight from your computer to the garment within minutes.

Screen printing shines in large-scale production. Once the screens are ready, printing becomes fast and efficient, making it highly economical for bulk orders. However, the initial preparation makes it less practical for on-demand or small-batch projects.

Cost and Upfront Investment

DTG printing has a higher cost per unit for large orders but minimal setup expenses. You can print as few as one item without worrying about order minimums, which suits small businesses, artists, and eCommerce sellers testing new designs.

Screen printing, on the other hand, requires a higher upfront investment due to screen setup and materials. But when printing in volume, it quickly becomes the more affordable option. The price per piece drops significantly as order size increases.

How To Choose The Right Type of Printing for Your Product?

Your choice depends on the kind of artwork you create, the number of products you need, and the flexibility you want in production.

When to Choose DTG Printing

DTG printing is your best bet when creativity and customization are top priorities. Because it prints directly from a digital file, you can reproduce photorealistic images, intricate artwork, and full-color designs with precision.

It’s especially useful if you:

Want to print small quantities or single items
Run a print-on-demand or eCommerce store where products are made only when ordered
Regularly test new designs or update your product catalog
Prefer not to hold inventory or manage storage

When to Choose Screen Printing

Screen printing remains the go-to choice for bold, simple designs and large-volume orders. Its setup process may take longer, but once the screens are ready, it becomes highly efficient and cost-effective for bulk production.

This method is ideal if you:

Need to print hundreds of garments quickly
Have designs with solid shapes, logos, or text-based graphics
Want vibrant, long-lasting prints that can withstand heavy use
Are producing merchandise, uniforms, or promotional apparel

Making the Final Decision

Before you choose, ask yourself:

Does your design have fine details or gradients?
Are you printing in small batches or bulk quantities?
Do you want to manage inventory, or would you rather print on demand?
How much upfront time and cost are you willing to invest?

In a Nutshell

If you’re running a dynamic online business or creating personalized designs, DTG printing offers the flexibility you need. But if you’re planning a large-scale production with simple, bold graphics, screen printing is the more efficient choice.

In the end, the “best” method isn’t universal — it’s the one that aligns with your goals, workflow, and audience expectations.

FAQs

Which printing method lasts longer – DTG or screen printing?
Screen printing generally lasts longer because it uses thicker layers of ink that sit on top of the fabric, making it highly resistant to washing and wear. DTG prints can still hold up well with proper care, but they may fade faster over time, especially on garments that are washed frequently or not pre-treated correctly.

Is DTG printing worth it for small businesses or clothing brands?
DTG printing is ideal for small brands, startups, or anyone testing new designs. Since you don’t need to order in bulk or invest in screens, you can produce high-quality prints on demand without keeping inventory.

Why is screen printing still popular if DTG is newer technology?
Even with digital advances, screen printing remains a favorite because of its durability, bold colors, and low cost at scale. For large batches, it’s faster and cheaper per unit than DTG.

Can DTG printing be done on dark or polyester fabrics?
DTG works best on 100% cotton, but it can print on dark shirts using a pre-treatment and white underbase layer. However, polyester and performance fabrics don’t absorb DTG inks as well. For synthetic materials, screen printing or sublimation is often a better choice.

Which method gives better color vibrancy?
It depends on the design. Screen printing produces strong, vivid colors with excellent opacity, perfect for solid, high-contrast artwork. DTG, on the other hand, delivers smoother gradients and detailed color blends, which makes it ideal for photo-realistic prints or complex illustrations.