T-Shirt Printing

T-shirt printing is a popular method for creating custom apparel, whether for personal use, promotional events, or business merchandise. There are several techniques available, each with its own advantages and best-use cases. Here’s a detailed breakdown:

1. Common T-Shirt Printing Methods

A. Screen Printing (Silk Screening)

  • How It Works: Ink is pushed through a mesh stencil (screen) onto the fabric.

  • Best For: Bulk orders (50+ shirts), simple designs with few colors.

  • Pros:

    • Cost-effective for large quantities.

    • Durable and long-lasting prints.

    • Vibrant colors on dark fabrics.

  • Cons:

    • High setup cost (not ideal for small batches).

    • Limited detail (gradients/fine lines can be tricky).

B. Direct-to-Garment (DTG) Printing

  • How It Works: Uses an inkjet printer to apply water-based ink directly onto the fabric.

  • Best For: Small batches, complex/full-color designs (photographs, gradients).

  • Pros:

    • No setup fees (great for one-off prints).

    • High detail and color accuracy.

  • Cons:

    • Slower for bulk orders.

    • Less vibrant on dark shirts (may require pretreatment).

C. Heat Transfer (Vinyl & Sublimation)

  • Heat Transfer Vinyl (HTV)

    • Cut vinyl is heat-pressed onto the shirt.

    • Best For: Simple designs, text, sportswear.

    • Pros: Durable, good for small batches.

    • Cons: Stiff feel, may crack over time.

  • Dye Sublimation

    • Ink turns into gas and bonds with polyester fabric.

    • Best For: All-over prints, light-colored polyester shirts.

    • Pros: No fading, seamless prints.

    • Cons: Only works on polyester or poly-coated materials.

D. Plastisol Transfer Printing

  • A hybrid of screen printing and heat transfer.

  • Best For: Medium batches with multi-color designs.

  • Pros: No color limits, good for detailed logos.

  • Cons: Slightly stiff feel, requires heat press.

E. Discharge Printing

  • Uses bleach-like agents to remove dye from the shirt, then adds new color.

  • Best For: Soft prints on 100% cotton.

  • Pros: Extremely soft finish, vintage look.

  • Cons: Works best on dark garments, limited color options.

2. Choosing the Right Method

Factor Best Method
Small Quantity DTG, Heat Transfer Vinyl
Large Quantity Screen Printing, Plastisol
Full-Color Art DTG, Sublimation
Dark Shirts Screen Printing (Plastisol)
Light Shirts DTG, Sublimation
Soft Feel Discharge, Water-Based Ink

3. Tips for High-Quality Prints

  • Design: Use vector graphics (for scaling) and 300 DPI resolution.

  • Fabric: 100% cotton works for most methods; polyester is best for sublimation.

  • Color Separation: Simplify colors for screen printing.

  • Washing: Turn inside out, wash in cold water to prolong print life.

4. Cost Considerations

  • Screen Printing: Cheaper per unit in bulk (~$3–$8 per shirt for 50+).

  • DTG: Higher per-unit cost (~$10–$20 for one shirt).

  • Sublimation: Best for polyester (~$10–$30 per shirt).

5. Eco-Friendly Options

  • Water-based inks (softer, less toxic).

  • Organic cotton shirts with eco-friendly dyes.

Final Thoughts

If you need durable, bulk prints, go with screen printing. For detailed, small batches, DTG is ideal. Sublimation is perfect for all-over designs on polyester, while HTV works well for simple logos and text.

Would you like recommendations based on a specific project?