If you're getting custom apparel made for the first time, you've probably come across the two big names in t-shirt printing: Direct-to-Garment (DTG) and screen printing. They're the most popular methods used today, but they work very differently and each has strengths depending on your project.
At Halo Print Co, we use both methods every day. Knowing which one fits your design, order size, and timeline will save you money and ensure the finished product looks exactly how you want.
How DTG Printing Works
DTG uses a specialised printer to spray water-based inks directly onto the fabric, similar to how a paper printer works. The design soaks into the fibres for a smooth, soft finish.
Best for:
- Small runs (under 26 shirts)
- Detailed designs with gradients, photos, or many colours
- One-off custom gifts or limited edition merch
Pros:
- No minimum order
- Unlimited colours at no extra cost
- Soft to the touch, no heavy ink feel
- Fast setup, quick turnaround
Cons:
- Per-shirt cost higher for bulk orders
- Works best on 100% cotton
- Less effective on dark synthetic fabrics
How Screen Printing Works
Screen printing pushes thick plastisol ink through a mesh stencil onto the fabric. Each colour in your design needs its own screen, then the inks are cured under heat for a long-lasting finish.
Best for:
- Bulk orders (26+ shirts)
- Simple designs with bold, solid colours
- Uniforms, events, large-scale merch drops
Pros:
- Cost-effective at higher volumes
- Extremely durable - lasts the life of the garment
- Bold, vibrant colours that pop
- Special inks available (metallic, glow, puff)
Cons:
- Higher setup cost for small runs
- Each additional colour adds cost
- Less suited to photo-quality artwork
DTG vs Screen Printing: At a Glance
- Order size: DTG for under 26, screen printing for 26 and up.
- Design complexity: DTG handles photos and gradients, screen printing handles bold colour blocks.
- Cost: DTG cheaper for small runs, screen printing cheaper at scale.
- Durability: Both last well; screen printing has a slight edge over many washes.
- Feel: DTG is softer, screen printing has a slight texture.
Which Should You Choose?
If you're testing a design, doing a small drop, or want detailed artwork - go DTG. If you're ordering for a team, an event, or a brand launch with simple bold colours - go screen printing. And when you're not sure, we'll always recommend the right method based on your design, garment, and timeline.
Ready to get started?
Ordering 26 or more? Get a price. Smaller order? Start a Quick Order. Want to talk it through? Book a consult.