Custom T-Shirt Printing Methods for Bulk Orders: Screen Printing, Heat Transfer, DTG Compared

If you’re sourcing custom t-shirts for your business—whether for branding, retail, or events—choosing the right printing method can save you money and ensure your design looks great. Let’s break down the 3 most popular methods: screen printing, heat transfer, and DTG (direct-to-garment). We’ll compare costs, quality, and when to use each for your bulk orders.

1. Screen Printing: Best for Large Orders (500+ Units)

silk-screen-printing

How It Works

Screen printing uses mesh screens for each color in your design. Ink is pushed through the screen onto the fabric with a squeegee, creating bold, vibrant prints. It’s the oldest method and ideal for simple, solid designs.

Pros

  • Low cost per unit for large orders: Prices drop significantly when ordering 500+ shirts. For example, a 1-color design might cost **$0.80/shirt for 1,000 units** (vs. $1.50/shirt for 100 units).
  • Durable: Ink sinks into the fabric, lasting 50+ washes—great for workwear or outdoor events.
  • Vibrant colors: Perfect for matching Pantone colors and solid logos.

Cons

  • High setup fees: $50–$100 per color for screen creation, making small orders expensive.
  • Design limits: Hard to print gradients or photos; max 6–8 colors per design.
  • Long lead time: 7–14 days for large orders due to screen preparation.

Best For

  • Uniforms, event tees, or any order over 500 units with simple, bold designs.

2. Heat Transfer: Flexible for Medium Orders (100–500 Units)

How It Works

There are two types:

 

  • Sublimation: For polyester fabrics. Design is printed on paper, then heated to transfer ink as gas into the fabric (great for photos).
  • Vinyl transfer: Colored vinyl is cut into your design and heat-pressed onto the shirt (works on most fabrics, including cotton).

Pros

  • Design flexibility: Handles gradients, photos, and multi-color designs with no color limits.
  • Low minimums: Viable for 100–500 units, with setup costs around $30–$50.
  • Fast turnaround: 3–7 days for standard orders (no screen drying time).

Cons

  • Fabric limits: Sublimation only works on polyester; vinyl may crack after 30–40 washes.
  • Higher cost than screen printing for large orders: $1.20/shirt for 1,000 units vs. $0.80 with screen printing.

Best For

  • Boutique brands, retail collections, or orders with detailed/photographic designs (100–500 units).

3. DTG (Direct-to-Garment): Ideal for Small Batches (1–200 Units)

UV Printing

How It Works

DTG uses digital inkjet technology to print directly onto fabric, like a large printer. It uses water-based inks and can print unique designs on each shirt.

Pros

  • No setup fees: Perfect for small orders or personalized designs (each shirt can have a different print).
  • Eco-friendly: OEKO-TEX certified inks, ideal for buyers needing sustainable options.
  • Soft feel: Ink sits lightly on the fabric, comfortable for premium cotton tees.

Cons

  • Slower production: 15–20 shirts/hour vs. 300+/hour for screen printing.
  • Higher cost at scale: $2.50/shirt for 100 units (cost parity with heat transfer at ~200 units).

Best For

  • On-demand event merch, small custom batches, or designs with gradients/photos (1–200 units).

How to Choose the Right Method

  1. Order Size First:
    • Small (1–200): DTG for no setup fees and quick turnaround.
    • Medium (200–500): Heat transfer for detailed designs; screen printing if design is simple.
    • Large (500+): Screen printing for the lowest cost per unit.
  2. Design Needs:
    • Photos or gradients? Use DTG or sublimation heat transfer.
    • Simple logos with 1–3 colors? Screen printing is your best bet.
  3. Budget & Timeline:
    • Tight budget for large orders? Screen printing saves money, even with longer lead times.
    • Need 50 shirts in 3 days? DTG is faster and requires no minimums.

Ready to Print Your Bulk Order?

Not sure which method works best? At TonySourcing, we help you test samples of all 3 methods and get a custom quote based on your order size, design, and fabric. Contact us today to start sourcing high-quality custom t-shirts that fit your budget and brand.

 

Remember: The key to a successful bulk order is matching the printing method to your needs. Use this guide to make an informed choice and avoid costly mistakes!

 

Need help with sourcing? We specialize in connecting global buyers with reliable China factories. Get a free consultation for your custom t-shirt project.

Tony Chen

Tony Chen, the founder of TonySourcing.com & TonyPromos.com He is Professional merchandiser in China since 2011, Now he have quote a lot of Professional knowledge for all kind of Toys and Promos item.

Leave a Reply