The Best Printing Methods for Custom Merchandise
Hey! Thinking about getting some custom merchandise printed, but not sure which method to choose? Don’t stress – Halo Print Co has you covered.
Back in the day, custom tees usually meant dodgy iron-on transfers that peeled off after one wash. Fast forward to today, and printing technology has levelled up in a big way. Whether you’re a small business owner, an event organiser, or just someone wanting personalised gifts, the right printing method makes all the difference.
At Halo Print Co., we offer four professional printing methods – Screen Printing, Direct-to-Garment (DTG), Direct-to-Film (DTF), and Embroidery – so no matter your order size, budget, or design, we can make your merch look incredible.
Choosing the right method affects more than just how your design looks. It determines how long it lasts, how much it costs per piece, and whether people will actually enjoy wearing or using it. That’s why it pays to understand what each method offers.
Let’s break it all down.
Screen Printing: The Bulk Order Legend
If there’s a king of custom merchandise printing, it’s screen printing. This tried-and-true method has been around for decades – and for good reason. It’s reliable, durable, and perfect for large orders.
How It Works
Screen printing uses mesh stencils (“screens”) and plastisol inks that are pushed through the mesh onto the fabric. Each colour in your design needs a separate screen, so multi-colour prints involve more setup.
Why It’s Great with Halo Print Co
Cost-efficient for large runs: While setup costs are higher, the per-unit price drops significantly as your order size grows. The real sweet spot is 100+ pieces.
Durability: Screen prints are built tough. The ink bonds with the fabric fibres and often outlasts the garment itself.
Special effects available: Metallic foils, glow-in-the-dark, and puff inks give your design extra wow-factor.
Works across fabrics: Best on cotton and blends, but also effective on polyester.
When to Use Screen Printing
Corporate uniforms or event merchandise
Large-scale promotions (festivals, campaigns)
Clothing brands needing consistent, bulk-quality production
Direct-to-Garment (DTG): Precision for Small Runs
Need just a handful of shirts, but with high detail? DTG is your best mate.
How It Works
DTG uses a specialised inkjet printer to apply eco-friendly water-based inks directly onto the fabric. Think of it as printing on paper – but for textiles.
Benefits at Halo Print Co
No minimum order: Perfect for 1–50 pieces.
Design freedom: Handles complex artwork, gradients, photos, and unlimited colours.
Soft finish: The water-based inks sink into the fibres, leaving no heavy texture.
Eco-friendly: We use non-toxic inks that keep colours vibrant while being kind to the planet.
When to Use DTG
Small businesses testing designs before going big
Artists or designers selling unique, one-off prints
Personalised gifts or family events
Direct-to-Film (DTF): The Versatile All-Rounder
DTF is one of the newest players in the custom print game, and it’s quickly becoming a favourite for its flexibility.
How It Works
Designs are printed onto a special film, then transferred onto fabric using heat and pressure. The result is a durable, flexible print with strong colour.
Why DTF at Halo Print Co is a Winner
Works on many fabrics: Cotton, polyester, blends – no problem.
Durability: Wash-resistant and crack-resistant.
Detailed prints: Handles fine details with sharp accuracy.
Versatility: Can even be applied to items like bags, caps, and hoodies.
When to Use DTF
Orders that need mixed garments (some tees, some hoodies, some caps)
Fast turnaround projects with detailed designs
Clients wanting strong colours on dark or light fabrics
Embroidery: Premium & Professional
When you want your merch to look sharp and last forever, embroidery is the way to go.
How It Works
Embroidery machines stitch your design directly into the garment using coloured threads. It creates a textured, high-quality look.
Why People Love Embroidery with Halo Print Co
Premium finish: Perfect for logos and branding.
Long-lasting: The stitching won’t fade or crack – it usually lasts as long as the garment.
Professional look: Elevates uniforms and business apparel.
Versatility: Works brilliantly on caps, polos, jackets, and hoodies.
When to Use Embroidery
Corporate uniforms and staff apparel
Headwear like caps and beanies
Premium merchandise where quality impression matters
Choosing the Right Printing Method
So, which one’s right for you? Here’s a simple framework Halo Print Co uses to guide customers:
1–25 pieces → DTG or DTF (best for small runs and quick jobs)
25–100 pieces → Depends on design and garment type – Screen Printing, DTF, or Embroidery could all fit
100+ pieces → Screen Printing for the best value and speed
Premium look → Embroidery for uniforms, hats, and polished merch
