Direct-to-Garment (DTG) and screen printing are two staple methods in the textile printing business. Screen printing has been around for centuries, while DTG first came up in the 1990s. Today, these two methods are often pitted against one another, as they both print directly onto the substrate. However, these two are distinctively different from each other and have their strengths and drawbacks.
This guide will explore how they differ and help you determine which one suits your needs.
What is DTG printing?
DTG printing is one of the most popular t-shirt printing techniques, with a market size of almost USD 2 billion in 2024, according to market figures. Compared to newer methods, DTG printing doesn’t use transfer films or paper. Instead, a specialized inkjet printer directly sprays the ink onto the substrate and cures it using a heat press. It’s the go-to method for printing on pure cotton as the ink gets absorbed more effectively.
What is Screen Printing?
Screen printing is another method that is popular for its durability and cost efficiency on bulk printing. It’s the only mainstream shirt printing method that uses a stencil-based process. First, you cut out your unique design on a stencil and paste it onto a mesh screen. Then, you squeegee the ink onto the screen. This allows the ink to pass through the cutout and leave the design impression.
It’s often a manual process, but newer processes involve the use of programmable machines that do the cutting of the stencil and pressing the ink onto the substrate.
DTG vs. Screen Printing: The Difference
DTG and screen printing are methods that both print the design directly onto the shirt, primarily cotton. They’re also known for producing vivid and durable finishes, as the ink gets infused deeper into the fabric’s individual fibers. However, beyond that, these two methods are distinct in their own right. Here’s where they differ.
Print quality and durability
Both print results produced by DTG and screen printing can be considered durable. However, there are levels to how durable the prints can be, and in this area, screen printing takes the upper hand. Screen-printed designs are often thicker and more rugged. The thicker layers of ink can hold up against multiple washes and are less susceptible to peeling and cracking.
On the other hand, while not quite as durable as screen-printed transfers, DTG has a more photo-quality print. After all, DTG transfers are digitally produced. This method produces higher resolution transfers with fewer blemishes and inconsistencies, which can be found in screen printing’s more manual process.
Design complexity
There’s a huge gap when it comes to design complexity between DTG and screen printing. You can expect a far more complex design from DTG, as it’s the specialized printer handling the process. Screen printing is often limited to simple and bold graphics as it requires a separate stencil for each design element. But this is not to say that screen-printed designs are boring. There are specialized inks that offer different, more specialized textures that add special effects to your design.
Color vividness
Screen printing uses plastisol or water-based inks that are much thicker and more opaque than DTG inks. These inks sit on top of the fabric, instead infusing into it like DTG does. As a result, the colours appear bolder, more solid, and more vibrant, especially on dark shirts.
With DTG, the ink is water-based and has a thinner consistency. It’s designed to soak into the fibres of the shirt, which gives a soft feel, but can also cause colours to look muted or washed out, particularly on darker garments without proper pretreatment.
Fabric suitability
You’ll often see cotton fabrics as the primary substrates for DTG and screen printing. That’s because natural fibers better absorb inks and have a more stable surface. However, unlike DTG, screen printing is a notch more versatile.
Polyester or blended fabrics aren’t ideal for DTG, as the method is all about ink absorption, and these garments aren’t as absorbent and are more prone to dye bleeding. This is not a concern in screen printing. The method doesn’t need deeper ink absorption. The transfer can be durable enough without getting infused all the way through the fibers.
Production volume and speed
When it comes to speed and efficiency, screen printing is the clear winner for bulk orders. Once the stencils and screens are set up, each shirt takes just seconds to print. It’s why screen printing dominates in large-scale production, especially when the same design is printed across hundreds of shirts.
DTG, on the other hand, is slower. Each shirt is printed one at a time. Setup time may be minimal, but the actual printing and curing can take several minutes per shirt. This makes it ideal for small runs, custom pieces, or print-on-demand services, but inefficient for high-volume printing.
Cost
DTG and screen printing can both be cost-effective, although that depends on your production. Printing one-offs or smaller batches is ideal for DTG. You don’t have to pay for a complex setup or produce several stencils for one design. However, it becomes a different story with bulk orders.
It’s better to switch to screen printing in this case, as DTG’s process is slow and expensive. The printing may take 2 minutes more or less. But add to that the curing and other individual processes, and you might take a day or two, especially for complex designs. If you use screen printing, your single set of stencils can already print hundreds of t-shirts in a day. That’s fast, simple, and costs less.
Sustainability
DTG is generally considered more eco-friendly, especially when using water-based inks and printing only what’s needed. It produces minimal waste, needs no chemical-heavy cleanup, and is perfect for on-demand models, which cuts overproduction.
Screen printing can be wasteful in comparison. It often involves excessive ink, chemical-based screen cleaning, and wasted garments due to misprints during setup. However, eco-conscious shops are shifting to water-based inks and recyclable materials, reducing their environmental impact.
That said, both methods can be sustainable if handled responsibly. The choice depends on how the shop manages its process, from ink disposal to waste management and energy use.
DTG vs. Screen Printing: When to Choose?
Choosing between DTG and screen printing mainly depends on your project, preferred design, and budget.
Go for DTG if:
- You’re printing small batches or even just one shirt.
- Your design involves intricate details and elements.
- You need a quick turnaround without setup hassles.
- You want a softer print feel, especially for light-coloured cotton shirts.
Opt for screen printing if:
- You’re printing in bulk—like dozens or hundreds of shirts.
- Your design is simple and uses solid colours.
- You need long-lasting, stand-out prints, especially on black or dark fabrics.
- You want to keep per-unit costs low for large orders.
In short, DTG is perfect for custom, high-detail prints on demand, while screen printing is better for mass production and bold, long-lasting designs.
Conclusion
Both DTG and screen printing have earned their place in the garment printing industry for good reason. DTG printer brings precision, flexibility, and digital efficiency to the table. Screen printing delivers unmatched speed, boldness, and durability, especially at scale.
So which one’s right for you? It’s not a matter of which is better, but which fits your current project. Whether you’re printing 1 shirt for a gift or 500 for a team event, knowing the difference helps you get the most out of your print job.
Still can’t decide? Chat with LINKO today to know more about their best DTG printing essentials!
