What’s the Best Method for Printing T-Shirts

Finding the best t-shirt printing method is one of the most important steps when starting a t-shirt business. The bad news: there’s more than one correct answer.

The ideal printing method for your t-shirt printing business depends on several factors, like the fabric type, t-shirt volume, your design vision, and your budget and time constraints.

For example, do you want to buy your own machines and print the t-shirts yourself? Or do you prefer to have a print-on-demand service fulfill your orders? If you choose the dropshipping business model, suppliers will even ship out your orders to customers under your label.

In this post, we’ll examine the top t-shirt printing methods for customizing your own shirts or making designs to sell. We’ll discuss the advantages and disadvantages of each shirt printing option, helping you make an informed choice.

Let’s get to it.

1. DTG printing

DTG, or direct-to-garment printing, is one of the most popular t-shirt printing techniques on the market right now. It’s also more recent than some of the other methods we’ll cover.

How does DTG work?

The easiest way to explain garment DTG printing is that it’s like printing on paper but on fabric. This means that, just like your desktop printer at home, the ink is jetted directly on the material to create the design.

But unlike paper printing, there’s an added key step. When printing on fabric using DTG, the product must be pre-treated before the ink is applied. This ensures that the ink will lock into the garment’s fibers.

Learn more: DTG vs. Screen Printing

The DTG t-shirt printing method enables one-off printing. That’s why this printing method is best for smaller businesses that want to work with custom t-shirts (or custom apparel in general) and don’t have a high order volume. Another major plus of the DTG t-shirt printing method? You can test different designs and sell on demand without holding tons of t-shirts in inventory. And you’ll still get the best t-shirt printing quality.

Direct-to-garment printing process. Source: Printful

DTG printing machines

To print t-shirts using DTG, you’ll need a DTG printer with special water-based inks that can bond with the fabric (preferably cotton or high cotton content fabrics). The machine (or machines, depending on your chosen process) applies a pre-treatment solution to the fabric’s surface. Then, the ink is jetted onto the pre-treated area, creating a printed design in just minutes.

This digital equipment is not cheap, so if you plan to buy your own machines, prepare for a significant upfront investment. Alternatively, you could rely on a print-on-demand provider like Printful who has top-notch equipment and is ready to print your t-shirts as soon as an order comes in.

All you have to do is connect your online store to Printful, and we’ll automatically fulfill, pack, and ship your order to your customer on your behalf.

DTG printing base. Source: Printful

DTG printing curing. Source: Printful

Fabric compatibility

DTG printing works best on 100% cotton garments but is also suitable for cotton blends. Synthetic fabrics are not recommended as DTG chemistry is not generally designed for them.

Since dark-colored fabrics can easily absorb the lighter colors of the ink, a white under base is always printed on these fabrics to create a neutral base for the subsequent colors printed on top. This guarantees that your design’s colors stay vibrant and accurately displayed. For this printing method, pre- and post-treatments are also necessary, not to mention special care instructions to make sure the products last longer.

Pros 

• No setup preparation (like films or meshes)

• Simple and efficient process

• Allows one-offs

• Perfect for small-to-medium businesses

• Often a more sustainable practice than screen printing as it avoids overproduction and creates minimal waste

• Long-lasting prints

• High-quality results and precision for complex designs

• Soft to the touch and breathable

• Nearly no color limitations with generally vibrant outcomes

Cons 

• Needs expensive equipment that requires special knowledge and heavy maintenance care

• Challenging to precisely match a very specific design color despite the expansive color range

• Needs pre-treatment and post-treatment

• Not a cost-effective option for large orders with the same design

• Doesn’t work well with non-cotton fabrics

Best for

DTG printing is ideal for more detailed and complex designs with unlimited colors and nuances you want to print on cotton-based apparel. It can manage nearly any design, from simple to complex. It also produces precise, accurate results and high-quality prints great for artistic designs or photos.

Learn more: Best Quality T-Shirts for Printing

2. DTF (direct-to-film) printing (or PET film transfer printing)

DTF stands for direct-to-film printing, one of the most versatile t-shirt printing methods available in the industry. Different from the previous, this t-shirt printing technique requires a film to transfer the design to your t-shirt. The process can be done with different types of fabric. 

How does DTF work?

Peeling off the PET film during DTF printing. Source: Printful

In DTF printing, the design is first printed on a special PET film with water-based inks and a powder that helps transfer designs. It’s then printed onto the t-shirt. The transfer from one surface to the other is done with a heat press machine, making the film peel off and leaving an exact print on the garment.

Direct-to-film printing process Source: Printful

DTF machines

To print a t-shirt using the DTF method, you would need to invest not only in equipment like a heat press machine but also in materials like film and powder, as well as the pre- and post-treatments for durable and high-quality prints.

Direct-to-film printing machine in action. Source: Printful

Fabric compatibility

One of the greatest advantages of DTF printing compared to other t-shirt printing methods is its versatility. It can be used on a wider variety of fabrics like cotton, polyester, fleece, nylon, and blended fabrics.

Learn more:

• DTF vs. DTG Printing

• DTF vs. Sublimation Printing

• DTF vs. Screen Printing

Pros

• High-quality results for detailed prints

• Allows more colors and shades (for example, it doesn’t require separate layers for design elements or colors, like screen printing)

• Works on different types of fabric

Cons

• More steps, slower process

• Higher cost for machines and materials (PET film and powder)

• Not eco-friendly, the films generate more waste

• Thicker prints compared to DTG

• Transparent elements don’t work well

Best for

Just like DTG, DTF printing is the perfect choice for elaborate designs with a wide range of colors and details. It’s also excellent for those who want to print many t-shirts with the same design. 

Learn more: What You Need to Know about Direct-To-Film Printing.

3. Screen printing (or silkscreen printing)

Screen printing, or silkscreen printing, is one of the oldest t-shirt printing methods around. And one of the most efficient, too! Screen printing offers vivid, durable t-shirt designs in a cost-effective way. 

How does screen printing work?

The screen printing process involves a stencil (that functions as a template), a mesh screen, and a squeegee or a straight blade to transfer your design to the t-shirt.

First, a stencil is created of the design and placed on a mesh screen. It’s important to block all areas that won’t receive the design so the ink will only go through the open spaces.

Once the stencil is placed onto the mesh, the ink is poured over it and pressed using the squeegee or blade to reproduce the design on the fabric. After that, excess ink is wiped off, and the t-shirt is laid out to dry.

Screen printing process. Source: Unsplash

Screen printing machines

Although it sounds like something that’s done manually, there are screen printing machines designed to automate the process and help you scale your own printing business. But if you’re thinking of starting small, here’s the equipment and material you’ll need:

• A computer with the essential software to prepare your designs

• An inkjet printer to create the film positive that’ll generate the stencil

• Screens made of a fine mesh that’s pulled over a frame (depending on how many different types of artwork you’ll use, you may need different sheets of mesh)

• A screen drying cabinet or a clean room with safe lighting

Screen printing setup. Source: Unsplash

Fabric compatibility

Natural fabrics like cotton, silk, and wool are the best for screen printing. Although natural and synthetic blends can also be screen printed using this technique, you should avoid 100% synthetic blends like polyester, spandex, and lycra.

Pros

• High-quality, long-lasting prints

• Cost-effectiveness for larger orders

• Compatible with many different fabrics

• Fast and affordable for large quantities of the same design (average of 25 pieces per design)

Cons

• Long process, not ideal for small businesses that want to sell on demand

• Not ideal for detailed designs

• Limited number of colors

• Expensive for small quantities and designs with many colors

• Not very eco-friendly since the process uses a lot of water, and the screen printing ink is usually plastisol-based (not biodegradable)

Best for

This t-shirt printing technique is recommended for one-color designs and bigger businesses with a higher demand for mass production. For smaller orders and more intricate designs, DTG would be the more logical choice.

4. Sublimation printing (also known as dye sublimation and all-over printing) 

Sublimation is the transition of a substance from a solid state to gas when it’s exposed to high temperatures and pressure. And that’s how this printing process got its name: it was thought that the dye turned to gas when printing. Now, it’s understood that there is some liquefaction of the dye, but the original term is still widely used, along with the technically correct one: dye diffusion.

In this printing method, the substance is a special type of liquid dye that penetrates the fabric to generate colorful designs by changing not only its color but also its texture. As a result, sublimation printing, also known as dye sublimation or digital sublimation, is a technique that works well for garment printing. 

In fact, it’s become one of the most popular methods for brands that sell t-shirts, especially all-over print shirts.

How does sublimation printing work?

The printing process is pretty simple. First, print the design onto special heat transfer paper. Then, apply heat to the transfer paper so the ink will penetrate the t-shirt.

Sublimation printing. Source: Printful

Sublimation machines

To make sublimated t-shirts, you need a heat transfer printing machine (a sublimation printer or heat press machine) with the specific transfer paper and ink.

When using older printers, pay attention to the fabric to ensure it doesn’t wrinkle during printing. It only happens if the fabric and the paper aren’t aligned—something you don’t need to worry about in newer printers.

Fabric compatibility

If you’re thinking of working with cotton t-shirts, forget about sublimation. This technique is made for synthetic fabrics like polyester.

Pros

• More colorful designs

• More resistant prints that endure more washes

• Vivid colors

• Smooth texture

Cons

• More steps, slower process

• More preparation may affect the overall cost

• Requires more advanced knowledge

Best for

Dye sublimation, or all-over printing, is perfect for all-over print t-shirts. But since the printed design must be on transfer paper each time a new t-shirt is made, it’s not the most cost-effective printing method for bulk orders. This makes it more adequate for on-demand production.

Learn more:

• Sublimation vs. Screen Printing: Which Method Is Best for Your Business?

• Guide to Cotton, Polyester, and Blended Fabrics

• How to Make Custom All-Over Print Shirts

5. Other t-shirt printing methods

Now that we’ve learned the basics about the most prominent printing methods out there, it’s time to explore other t-shirt printing options. Who knows? Maybe the garment printing solution you’ve been looking for is off the beaten path.

Plastisol transfers

Plastisol transfers would fall under the screen printing category, but with one extra step: the design is applied on a special printing paper.

How do plastisol transfers work?

The first part of the process is exactly like screen printing, using a stencil and a mesh screen. But instead of printing directly onto the garment, the design is first digitally printed on plastisol transfer paper, which is then printed on your t-shirt using a heat press.

This extra step makes the process suitable for a set of specific needs, but the main one is that plastisol transfer allows you to set up for t-shirt printing in advance. Meaning, you prepare the transfer paper once and then you can print the design on a garment whenever you need in a fast, simple way.

Pros

• Suitable for tougher fabrics (like fleece)

• Durable prints with similar quality to screen printing

• A good option for live printing or printing in front of an audience

Cons

• Adds an extra step to the process

• Requires knowledge to avoid mistakes

• Not ideal for large orders since it takes more steps and materials, which makes the process slower

Heat press printing

This is probably the least expensive way to start your printing adventures. All you’ll need is a regular inkjet printer, special printing papers, and a relatively cheap heat press machine.

How does heat press printing work?

In many ways, it’s similar to dye sublimation, but the science behind it is a bit different. In both methods, the design is printed on transfer paper and then transferred to the fabric using heat and pressure. With the heat press method, the design simply adheres to the fabric, creating a layer on top of the t-shirt. With dye sublimation, the ink becomes part of the fabric, actually dying the t-shirt.

Pros

• Probably the least expensive method around

• A straightforward process

• Suitable for small quantities and complex designs

Cons

• Not suitable for fabrics with heat sensitivity

• Low-quality results on darker fabrics

Vinyl cutting (or vinyl printing)

Vinyl cutting, also known as vinyl printing, is a versatile take on the heat press technique and is suitable for both mass printing and smaller quantities.

How does vinyl cutting/vinyl printing work?

First, the design is cut from a vinyl sheet using computer-aided design (CAD) software and a laser cutter. Then, the design is transferred to the t-shirt using a heat press machine. You can choose from a variety of vinyl colors, and the result is a vibrant, high-quality print.

The downside? It tends to make the fabric lose flexibility, which makes vinyl printing better suited to smaller prints, like branding, icons, or text.

The vinyl printing process. Source: Custom One

Pros

• Durable and high-quality results

• Versatile method—works for small and large quantities

Cons

• Requires extra equipment (the vinyl cutter)

• Not suitable for big prints

Discharge printing

This is almost like a reverse t-shirt printing technique: instead of applying ink to the t-shirt, you remove the dye from the fabric to create a negative print. It’s not the most flexible t-shirt printing method, but the result is a unique, vintage-looking print.

How does discharge printing work?

Discharge t-shirt printing will only work with natural fabrics (like cotton). The fabric color also plays a role—some colors will bleach better than others. The design can be applied to the t-shirt using screen printing, but the ink is mixed with a special product that will remove the original dye and replace it with your chosen color.

Discharge printed t-shirts. Source: Magna Colours

Pros

• Soft-to-touch prints with vibrant colors

• Suitable for complex and simple designs

• Unique retro effect

Cons

• Works only with natural fabrics

• Inconsistent results—colors might vary from print to print

Belt printing

This method allows you to apply your design all over the t-shirt, including the collar and sleeves. The result is a seamless all-over print, but the process isn’t the most cost-effective, which means this technique isn’t common in retail.

Belt printing machine. Source: Systematic Automation Inc.

How does belt printing work?

A belt printing machine puts the design on a roll of fabric, similar to screen printing. Usually, it’s a one-color design to keep the fabric soft. This technique can be combined with others, like traditional screen printing, to complement the design. Once printed, the roll of fabric is cut to create the t-shirt.

Belt printed t-shirt combined with other printing methods. Source: Superior

Pros

• Seamless all-over prints

Cons

• Requires expensive equipment

• The color spectrum might be limited

Old-school printing methods

Finally, let’s talk about more traditional customization methods that don’t necessarily require machinery and allow for homemade personalizations.

Resist dyeing

This is the technique behind the world-famous tie-dye effect. The idea is to prevent the ink from coming into contact with some sections of the fabric, creating a textured look as the final result. In tie-dye, parts of the fabric are tied together before dipping it in dye. Older traditional techniques like shibori and bandhani have a similar process.

Apart from manual methods (like tying and clamping), you can use substances like waxes and other chemicals to prevent the ink from penetrating parts of the fabric.

Tie-dye t-shirt combined with embroidery. Source: Printful

Airbrushing

If you like to exercise your creativity and experiment, this can be a really fun t-shirt printing option. Although it requires a lot of technical mastery, airbrushing has very specific results reminiscent of graffiti. The process is straightforward: you’ll need an airbrush gun, paint, and a stencil, and you’re ready to get to work!

It’s a good idea to do a test run first, as not every fabric and color suits this technique. It’s also important to remember that airbrush prints are not durable—the ink tends to come off over time. Other than that, this technique can help you create very unique looks.

Airbrush t-shirt. Source: Etsy

Time to choose the best t-shirt printing method for you!

And now you know: there’s a LOT of different t-shirt printing methods. To choose what’s best for you, start with the pros and cons of each printing method. See which pros and cons are your dealbreakers, so that your chosen printing method will make your t-shirt business thrive. This involves not just assessing quality and fabric compatibility. It’s also important to evaluate initial investments and ongoing expenses, including equipment, materials, training, personnel, and more.

Considering your business goals and the product quality standards you expect, it may be worth partnering with a 3rd party print provider. Look into print-on-demand possibilities, a fulfillment method that allows you to start selling custom t-shirts online with almost zero initial capital.

Experts will manage your products’ printing, packaging, and shipping to customers, allowing you to focus on other aspects of your business. You’ll also have the opportunity to explore other premium customization options, like embroidery and knitwear.

Read next:

• How to Start a Clothing Brand: a Complete Step-by-Step Guide

• Types of Shirt Printing: Picking the Best Method for Your Brand