DTG vs Screen Printing (vs Embroidery, Sublimation, and Cut and Sew)
Not all printing methods are created equal, and choosing the wrong one can ruin your margins or your product quality. Here is when to use each.
If you're starting a clothing brand, printing merch, or just trying to figure out the best way to bring your designs to life, this will save you time, money, and a lot of frustration. Not all printing methods are created equal, and choosing the wrong one can completely ruin your margins or your product quality.
Screen printing pushes plastisol ink through a screen onto a garment, and each color in your design requires its own screen. The biggest advantage is cost at scale: the more you print, the cheaper it is per piece. The downside is setup time, about 45 minutes per color, plus minimum order quantities and two to three week turnarounds. Screen printing is best for bulk orders with simple color palettes, no more than two colors.
Direct-to-garment, or DTG, is a high-end printer that prints directly onto the fabric, like printing a photo on paper but on a t-shirt. These printers hit up to 1600 dots per inch; your average screen print is around 100. Unlimited colors, photorealistic prints, no screens, no setup fees, and turnarounds are usually same day to three days for small runs. DTG is perfect for small batches, testing designs, print-on-demand setups, or any artwork where you're in a rush. It's the method we run in-house at PrintBliss, and we can always beat the turnaround time of any screen printing or embroidery.
Embroidery uses thread stitched directly into the garment. It's the most durable option, hands down, with a premium high-end look, which is why you see it on polos, uniforms, and hats. There are setup costs for digitizing your design, and pricing depends on stitch count and size. Ideal for corporate apparel, uniforms, and higher-end branded merch.
Sublimation is a dye process where the ink becomes part of the fabric instead of sitting on top of it. There's no feel to the print at all, and it's amazing for full-color, all-over designs. The catch: it only works on 100% polyester. Perfect for sports jerseys and performance wear.
Cut and sew is full-on custom manufacturing. You're not printing on blanks, you're creating the entire garment from scratch: fabric, weight, fit, dye colors, everything. Maximum control, but higher minimums, usually 48 to 400 pieces per design, and three to six month timelines. Best for established brands that are scaling.
How to choose: one to 20 pieces or a rush, DTG. 200 pieces or more with one or two colors, screen printing. Workwear or uniforms, embroidery. Polyester performance wear, sublimation. Fashion-forward, fully custom pieces, cut and sew.
This lesson is part of T-Shirt University, our free course on starting, launching, and maintaining a real apparel brand. Watch the full course and read every lesson at printbliss.io/university. And when you're ready to print, we're at printbliss.io/quote.