Not all printing methods are created equal, and choosing the wrong one can completely ruin your margins or your product quality. Here are the five main methods and when to use them.

Screen printing pushes plastisol ink through a screen onto the garment; each color needs its own screen. Its advantage is cost at scale, and it's perfect for bold, simple designs. The downsides: about 45 minutes of setup per color, minimum order quantities, and two to three week turnarounds. Best for bulk orders with one or two colors.

Direct-to-garment (DTG) prints directly onto the fabric, like printing a photo on paper but on a t-shirt. Up to 1600 DPI (your average screen print is around 100), unlimited colors, photorealistic prints, no screens and no setup fees, with same-day to three-day turnarounds. Perfect for small batches, testing designs, and anything in a rush.

Embroidery uses thread stitched directly into the garment. It's the most durable option, hands down, with a premium look, which is why you see it on polos, uniforms, and hats. Costs depend on stitch count and size, and there's a digitizing setup fee. Ideal for corporate apparel 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. No feel to the print at all, amazing for full-color all-over designs, but it only works on 100% polyester. Perfect for sports jerseys and performance wear.

Cut and sew is full custom manufacturing: you create the entire garment from scratch, choosing fabric, weight, fit, and colors. Maximum control, but higher minimums (usually 48 to 400 pieces per design), three to six month timelines, and more complexity. Best for established brands that are scaling.

The quick decision framework: 1 to 20 pieces or a rush order, DTG. 200+ pieces with one or two colors, screen printing. Workwear or uniforms, embroidery. Polyester performance wear, sublimation. Fashion-forward fully custom pieces, cut and sew.