DTG vs Screen Printing
The key difference between DTG (Direct-to-Garment) and Screen Printing is the process and economics: DTG uses inkjet technology to print directly onto fabric with no setup cost, making it ideal for small runs and complex designs. Screen printing pushes ink through mesh stencils, requiring setup per colour but becoming cheaper per unit at scale.
Head-to-Head
DTG Printing
Strengths
- No setup costs — print one unit or one thousand at the same per-unit colour cost
- Unlimited colours — photographic, gradient, and complex designs at no extra cost
- Soft hand-feel — water-based inks absorb into the fabric rather than sitting on top
- Fast turnaround — no screen preparation means 1–3 day production start
- Easy design changes — update artwork between units without additional cost
Best For
Screen Printing
Strengths
- Lowest cost per unit at scale — drops below €1/print at 500+ units per design
- Vibrant, opaque colours — Pantone-matched plastisol inks pop on dark garments
- Superior wash durability — properly cured screen prints outlast DTG by 2–3x washes
- Special effects available — puff, metallic, glow-in-the-dark, discharge, foil
- Consistent colour across thousands of units — no variation between prints
Best For
Detailed Comparison
| Criteria | DTG Printing | Screen Printing |
|---|---|---|
| Setup Cost | €0 | €25–50 per screen (per colour) |
| Cost at 50 Units | €3–5/unit | €5–8/unit |
| Cost at 500 Units | €3–5/unit | €0.80–1.50/unit |
| Max Colours | Unlimited (CMYK) | 1–8 spot colours |
| Wash Durability | 30–50 washes | 50–100+ washes |
| Hand Feel | Soft (water-based ink) | Thicker (plastisol) |
| Minimum Order | 1 unit | 50–100 units |
| Production Speed (500 pcs) | 3–5 days | 1–2 days |
Verdict
Our Recommendation
Choose DTG for small batches, complex designs, and when you need zero setup costs. Choose Screen Printing for runs of 300+ units with 1–6 colours where cost-per-unit and durability matter. The crossover point is typically around 150–200 units — below that DTG is cheaper, above that screen printing wins.
Common Questions
Frequently Asked
At what quantity should I switch from DTG to screen printing?
The crossover point depends on the number of colours, but generally screen printing becomes more cost-effective at 150–200 units for a single design. For 1–2 colour designs, the crossover can be as low as 50 units. For photographic prints, DTG may remain cheaper at any quantity.
Which method lasts longer after washing?
Screen printing lasts longer — properly cured plastisol prints survive 50–100+ washes without significant fading. DTG prints typically show noticeable fading after 30–50 washes. Pre-treating the garment and using quality DTG inks improves longevity, but screen printing still wins on durability.
Can DTG print on dark garments?
Yes, but it requires a white ink under-base layer, which adds cost (€1–2/unit extra) and slightly affects hand-feel. Screen printing handles dark garments more naturally with opaque plastisol inks. If your line is predominantly dark colours, factor in the white under-base cost for DTG.
Which is better for the environment?
DTG uses water-based inks with lower VOC emissions and generates less waste (no screens, no unused ink). Screen printing uses plastisol (PVC-based) inks that require chemical cleaning. Water-based screen printing is available as a greener alternative but at a premium cost.
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