How It Works: A stencil (or screen) is created for each color and ink is pushed through the mesh onto the fabric. Each color requires its own screen so designs are layered in multiple steps.
Best For: Bulk orders with simple designs, especially those with less than 6 colors.
Benefits: Highly durable and bright colors. For bulk orders, screen printing costs $2-$5 per shirt. It’s a cost-effective option for 
How It Works: A digital printer applies ink directly to the fabric. It produces high-detail, color-accurate designs. The ink bonds with the fabric, soft feel.
Best For: Small batches or highly detailed, multi-colored designs. Best for orders under 100 units, especially for complex images, like logos or photos.
Benefits: No setup costs, so ideal for low volume, custom orders. DTG can print up to 16.7 million colors so perfect for detailed artwork. Estimated 50% faster turnaround for small orders compared to traditional methods.
Considerations: Slower than screen printing, typically 20-30 shirts per hour. Best results on 100% cotton fabrics. Dark garments may need pretreatment for vibrant colors. It adds 10-15% to production time.
How It Works: Designs are printed on special transfer paper using inkjet or laser printers. Then, heat and pressure transfer the design onto the fabric.
Best For: Low-volume orders or custom designs with multiple colors. Promotional items, events or small batch runs.
Benefits: Versatile in design and color, can print on various fabrics. No setup cost so cost-effective for smaller orders. Production rates are faster for small batches, up to 50 shirts per hour.
Considerations: Durability can be lower than screen printing; designs can crack or peel after 30-40 washes. Works best on lighter-coloured fabrics. Dark fabrics may need advanced heat transfer material, which adds 10-20% to the cost.
Expert Advice: To ensure better durability, consider using higher-quality transfer materials. Particularly for designs on darker fabrics.
How It Works: 
How It Works: A machine cuts designs from colored vinyl sheets. Then, heat press the vinyl onto the fabric.
Best For: Simple designs, logos and text on t-shirts. Small batches and personalized items like sports uniforms or custom apparel.
Benefits: Vinyl is durable, designs won’t crack or fade over time. Excellent color vibrancy and great for clean edges. No ink is involved, so good for single color or small-scale designs.
Considerations: Not for complex or multicolor designs. Vinyl can feel heavy on the fabric and process is slower for large-scale production.
How It Works: Plastisol transfers print designs onto transfer paper using plastisol ink. Then, heat press it onto the fabric at 350°F for 10-15 seconds.
Best For: High-detail, multicolor designs. Suitable for small runs (20 units) and large orders (up to 1,000 units). Used for retail-quality prints, custom logos and event merchandise.
Benefits: Vibrant, sharp designs up to 50 washes. Plastisol transfers can be pre-produced and stored for 12 months. This allows for flexible production without compromising quality.
Considerations: Transfers may not work well on heat-sensitive fabrics. They require a higher transfer temperature. Print can feel heavier, may affect fabric breathability.
Pro Tip: For best results with plastisol transfers. Preheat the fabric for a few seconds before applying the transfer.
How It Works: Discharge printing uses water-based ink. Removes dye from dark fabrics. This leaves a soft, natural print that shows the fabric’s original color. The result is a smooth, breathable finish with no feel of thick ink.
Best For: Dark-colored fabrics and designs that need a soft feel. Used for vintage style prints or high-end fashion items.
Benefits: Vibrant prints on dark fabrics without adding extra ink. Print feels soft to the touch and blends with the fabric.
Considerations: Only works on 100% cotton fabrics. Colors may vary due to the fabric dye. The process takes longer due to post-printing treatment.
How It Works: Flock printing applies adhesive to the fabric. Then, it uses heat to bond small fibers (flock) to create a velvet-like finish. Fibers are applied with high-voltage electricity for precise placement.
Best For: Logos, bold text and designs that need raised, textured feel. Used in sports jerseys and high-end fashion items.
Benefits: The raised, textured finish stands out and adds premium quality to garments. Flock printing is durable. It lasts for 50 washes with no significant wear. It works on cotton and polyester blends.
Considerations: Flock printing is best for simple, low-color designs. Fine details may not translate well. The process costs 10-20% more than traditional screen printing. This is due to added materials and labor.
How It Works: Puff printing is a type of screen printing. Uses special ink with an expanding agent. Once heated, the ink puffs up and creates a raised, 3D effect on the garment.
Best For: Simple designs, logos or bold text that needs raised, tactile effect. Used for streetwear, casual apparel and creative branding.
Benefits: Puff printing adds depth and texture to designs, gives them a unique look and feel. Works on cotton and cotton blend fabrics and is durable up to 30-40 washes without fading or wear.
Considerations: Puff printing is not good for intricate designs. Its raised effect causes this. The process may add 10-15% to production cost compared to standard screen printing.
Types of t-shirt printing will impact your product’s quality, durability and cost. Each method has its own advantages. They are vibrant prints, high-volume production, and eco-friendly options. Use the right method for your design, fabric, and production needs. Make your t-shirts resonate with customers and stay relevant.
Knowing the strengths and limits of types of t-shirt printing. Lets you align decisions with your brand goals and customer expectations. For custom solutions, Achieve Sportswear provides t-shirt printing services. We have the expertise and flexibility to help your brand stand out. Contact us to get a free quote.
