6 Types of Shirt Printing Methods

Shirt printing, often referred to as screen printing, is an affordable and straightforward way to customise t-shirts with your own designs or logos. Whether you’re launching a new fashion label featuring original artwork or creating personalised shirts for a special event, there are plenty of innovative printing options to give life to your imagination.

The most popular types of shirt printing methods are Screen Printing and Direct to Garment (DTG) Printing. Other well-known decoration methods are Dye Sublimation, Vinyl Heat Transfers, Laser Transfers, Digital Full Colour Transfers, Resist Dyeing, DTF, Embroidery, Plastisol Transfers, and Airbrushing. Different t-shirt printing equipment is required for each technique.

1. Screen Printing: A durable and cost-effective technique using mesh screens to transfer ink onto fabric, ideal for bulk orders.
2. Direct to Garment (DTG) Printing: A method that prints complex, vibrant designs directly onto fabric using inkjet technology.
3. Dye Sublimation or All-Over Printing (AOP): A process that uses heat and special dyes to create vivid, long-lasting prints on polyester fabrics.
4. Vinyl Heat Transfers: Heat Transfer Vinyl (HTV) printing is a method that uses heat and pressure to transfer cut vinyl designs onto fabric, offering durability and vibrant results.
5. Laser Transfers: A decoration technique using laser printers and heat to create precise, full-colour designs on various fabrics.
6. Digital Full-Colour Transfer: A modern tee printing method that delivers high-resolution, vibrant designs on multiple fabric types.
7. Resist Dyeing: A traditional technique using tie-dye or batik methods to create unique, pattern-based fabric designs.
8.  Direct-to-Film (DTF) Printing: A method where designs are printed on PET film, coated with adhesive powder, and heat-transferred onto fabric for vibrant, durable prints.
9. Embroidery: A method of decorating t-shirts by stitching designs directly onto the fabric using thread, offering a professional, textured finish.
10. Plastisol Transfer Printing: A screen printing technique where designs are first printed onto transfer paper with plastisol ink and then transferred onto t-shirts using heat and pressure.
11. Airbrushing: It is a manual t-shirt printing technique where paint is applied using a spray tool and stencils, allowing for unique, custom designs but limited durability and scalability.

Dye sublimation is ideal for polyester fabrics, providing vibrant, full-colour results. Vinyl heat transfers and digital transfers offer versatility in design and fabric compatibility, with vinyl being particularly suited for bold designs. If you seek a more artistic, custom look, airbrushing offers creative freedom, although it’s not suitable for large orders due to its labour-intensive nature. Additionally, factors such as cost, turnaround time, and long-term durability should be considered based on your specific project needs.

Direct to Garment (DTG) Printing

Direct to Garment (DTG) printing is one of the fastest-growing methods for custom t-shirt printing due to its simplicity and efficiency. This process works similarly to a traditional paper printer, but instead of paper, it prints directly onto fabric. DTG is an excellent choice for printing photos or intricate designs on t-shirts, as its advanced inkjet technology can handle complex artwork without any colour limitations.

DTG Printing Process

DTG printing is ideal for creating t-shirts with vibrant logos or detailed designs. To get started, connect your DTG printer to a computer and select your desired image or graphic. Adjust the colour scale and range carefully to ensure accurate results that reflect the design’s original vibrancy. The printer will then transfer the design directly onto the t-shirt with minimal effort.

Pros & Cons of DTG Printing

One of the primary benefits of DTG is its ability to print soft, natural-feeling designs, as the ink bonds well with the fabric without adding bulk. There are no colour restrictions, enabling detailed patterns, images, or graphics in over 100 colours with exceptional clarity.

However, DTG prints may fade over time, especially after repeated washes. To maintain print quality, turn the t-shirt inside out before washing. DTG is best suited for small-scale projects rather than bulk orders due to slower production times.

You Might Want to Read: DTG Vs Screen Printing on T-Shirts

Screen Printing

Screen printing, also known as silk screen printing, is a time-tested technique that uses mesh screens to transfer ink onto fabric. It’s a popular choice among professionals for bulk orders due to its durability and cost-effectiveness.

Screen Printing Process

The screen printing for the tee-shirts process begins by stretching a nylon mesh screen over a wooden frame and covering the negative space with a waterproof blockage to prevent ink from passing through. Once the screen is prepared, ink is spread across it, transferring the design onto the fabric through the open spaces. Screen printing also offers creative options like puff printing, glitter finishes, and glow-in-the-dark designs to add unique touches to t-shirts.

Pros & Cons of Screen Printing

Screen printing’s thicker ink produces vibrant, long-lasting designs, making it an excellent option for simple designs with limited colours. It’s also highly cost-effective for bulk printing projects.

However, this method isn’t ideal for intricate or multi-coloured designs since each colour requires a separate screen, increasing time and complexity.

Dye Sublimation Printing

Dye sublimation printing, also known as all over printing, is a fantastic t-shirt decoration choice for light-coloured fabrics such as polyester, pre-treated materials, or cotton blends. This method uses heat and pressure to turn solid inks into gas, ensuring that the fabric absorbs the colours for a seamless and durable finish. It’s especially effective for large, detailed designs but may yield unpredictable results on non-polyester materials.

Dye Sublimation Printing Process

To start dye sublimation, you’ll need a sublimation printer, heat press, specialised inks, and release paper. Using a combination of heat and pressure, the design is transferred onto the fabric. The sublimation ink bonds directly with the fibres, resulting in vibrant, crisp designs that feel as soft as the original fabric.

Pros & Cons of Dye Sublimation Printing

Dye sublimation delivers unmatched vibrancy and durability on polyester fabrics, with designs that resist fading over time. It’s ideal for larger prints on light fabrics, as the unique vaporisation process ensures the colours blend easily into the material.

But this method has a significant limitation: it works only on polyester or polyester blends. It’s unsuitable for 100% cotton or dark fabrics because the sublimation ink cannot bond with these materials.

Vinyl Heat Transfers

Vinyl Heat Transfer is a growing favourite in the custom printing world due to its unmatched precision and clean finish. This technique uses heat and pressure to imprint designs onto fabric, making it a popular alternative to screen printing, especially for intricate, multi-coloured designs.

Heat Transfer Vinyl (HTV) Printing Process

Printing with vinyl heat transfers is straightforward if you have the right tools. You’ll need a heat press, heat-resistant sheets, a vinyl cutter, vinyl transfer paper, a computer, a printer, and inks.

1. Create or select a graphic design on your computer.
   Print the design onto vinyl transfer paper.
2. Use a vinyl cutter to trim the design for precision.
3. Preheat your heat press and adjust the pressure based on the fabric’s thickness.
4. Position the t-shirt face-up on the heat press plate and place the vinyl sheet on the desired area.
5. Apply heat and pressure, then peel away the vinyl sheet to reveal the design.

Pros & Cons of Vinyl Heat Transfers

Pros:

1. Highly durable: The heat fusion ensures designs stay intact after repeated washes.
2. Vibrant colours: Produces sharp and vivid results, even for multi-coloured designs.

Cons:

1. Time-intensive: The multi-step process can be tedious, especially for large orders.
2. Limited scalability: Best for small-scale projects or personalised items rather than bulk production.

Laser Transfers

Laser transfer printing is ideal for achieving high-resolution, full-colour images on t-shirts. This method relies on high-quality laser printers to transfer designs accurately onto fabric, making it perfect for digital images with complex colour gradients.

Laser Transfer Process

To create laser-printed t-shirts, you’ll need a laser printer, heat transfer papers, and a heat press.

1. Choose your design and customise it as needed on your computer.
2. Print the design onto heat transfer paper using a laser printer.
3. Position the transfer paper onto the t-shirt and use a heat press to imprint the design onto the fabric.
4. Remove the transfer sheet carefully to reveal the print.

Pros & Cons of Laser Transfers

Pros:

1. Excellent colour accuracy: Laser printers use CMYK or even white toner for vibrant prints on dark fabrics.
2. Versatility: Works on various fabric types and colours.

Cons:

1. Heat sensitivity: Fabrics that cannot handle high temperatures are unsuitable for this method.
2. Cost: High-quality laser printers and toner can be expensive.

Digital Full-Colour Transfers

Digital full-colour transfer is a modern and cost-effective printing technique known for its vibrant, high-resolution results. Unlike other methods, this technique does not require separate ink colours, making it perfect for detailed, multi-colour designs.

Digital Transfer Process

Digital Full Colour Transfer process is simple yet effective for a variety of fabrics, including cotton, polyester, and nylon.

1. Create or select a design on your computer.
2. Print the design onto thin vinyl transfer paper.
3. Trim the design (e.g., cutting out the inner parts of letters) for a polished finish.
4. Use a heat press to affix the design onto the t-shirt.

Pros & Cons of Digital Full-Colour Transfers

Pros:

Unlimited colours: The method supports CMYK toner and extended colour gamut inks.

Fabric versatility: Suitable for various materials, including cotton and synthetic blends.

Cons:

Single-colour designs may lack optimal results, as the method is tailored for vibrant, multi-colour prints.

Thin vinyl may not be as durable as other methods like screen or vinyl transfers.

Resist Dyeing

Resist dyeing is a traditional method with a unique artistic appeal. Popular DIY t-shirt printing techniques such as Tie-Dye and Batik fall under this category, creating distinctive patterns through the strategic application of dyes.

Resist Dyeing Process

1. Tie-Dye Method: Pinch and tie specific areas of the t-shirt with thread to resist dye penetration. Apply dye, let it set, then rinse and repeat with different colours for layered effects.
2. Batik Method: Apply wax or paste to the areas you want to resist colour. Submerge the fabric in dye, remove the wax, and repeat for multi-layered designs.

Pros & Cons of Resist Dyeing

Pros:

1. Endless variety: Each piece is unique due to the manual process.
2. Minimal equipment: Suitable for beginners or small-scale projects.

Cons:

1. Limited precision: Not suitable for replicating logos or specific images.
2. Time-consuming: The multi-step process may not be practical for large orders.

Direct-to-Film (DTF) Printing

Direct-to-film printing (DTF) is an advanced t-shirt printing method where designs are printed onto a special PET film, coated with adhesive powder, and then heat-transferred onto fabric. Unlike Direct-to-Garment (DTG) printing, DTF skips the need for garment pretreatment, making it a versatile and efficient option for custom apparel.

DTF printing stands out for its exceptional colour vibrancy and adaptability, making it ideal for bold and detailed designs across a variety of garments and accessories.

DTF Printing Process

1. Design the graphic and print it onto PET film using a DTF printer.
2. Apply a layer of adhesive powder to the printed film.
3. Cure the adhesive powder using a heat press or curing oven.
4. Transfer the film design onto the t-shirt by pressing it with heat.
5. Peel the film to reveal the vibrant, high-quality print.

Pros

1. Compatible with various fabrics, including polyester, cotton, and blends.
2. Produces vivid and bright designs that stand out on any base colour.
3. Prints sit on the fabric surface, ensuring excellent wear and tear resistance.
4. Suitable for detailed designs on small items like t-shirts, masks, and cushion covers.

Cons

1. Creates a plasticky texture and shiny finish on the print.
2. Less suitable for larger-scale printing due to the detailed process.
3. Requires more steps compared to simpler methods like DTG or dye sublimation.

Embroidery

Embroidery is a premium t-shirt customisation method that stitches designs directly onto fabric using colourful threads, creating a raised, textured finish that is highly durable and professional.

Embroidery is the go-to choice for businesses and organisations seeking a polished, high-quality look for their branded t-shirts or uniforms.

Embroidery Process

1. Convert the design into a digital embroidery file using specialised software.
2. Load the t-shirt into an embroidery machine and secure it with a hoop to keep the fabric taut.
3. Thread the machine with the required colours and let it stitch the design onto the fabric.
4. Once complete, trim any excess threads and inspect the design for accuracy.

Pros

1. Highly durable and long-lasting, withstanding frequent washes.
2. Offers a professional and premium look, ideal for corporate or workwear.
   Works well for simple logos, text, and small designs.
3. Suitable for a variety of fabric types, including thicker materials like polo shirts and jackets.

Cons:

1. Limited to small or simple designs due to thread detailing.
2. Less suitable for intricate, colourful, or photo-realistic images.
3. Can be expensive compared to printing methods, especially for large orders.
4. Takes longer to produce due to the stitching process.

Plastisol Transfer Printing

Plastisol transfer printing is a versatile indirect screen printing method that uses a plastic-based transfer sheet to transfer designs onto t-shirts. It is a simplified version of traditional screen printing, where the design is first printed onto a transfer paper, and then applied to the garment using heat and pressure. This process is ideal for businesses that need flexibility in producing custom designs with excellent durability and special effects.

Plastisol transfer printing offers a high-quality, versatile solution for custom t-shirt printing with the added benefit of special effects, making it a great option for unique, medium-volume customisation projects. However, it is better suited for smaller runs due to the setup time involved.

Plastisol Transfer Printing Process

1. Design Creation: The design is created and reversed, just like in standard screen printing.
   Preparing Transfer Paper: The transfer paper is placed under the screen, and ink is applied to the paper rather than directly onto the t-shirt.
2. Drying: The transfer paper is run through a conveyor dryer to remove excess moisture.
3. Adhesion Powder: Adhesion powder is sprinkled on the printed design to ensure better adhesion to the fabric and minimise blurring.
4. Heat Transfer: The ink is gelled in a conveyor dryer and then applied to the t-shirt using a heat press.
5. Peeling and Storage: The transfer paper is peeled off, revealing the design on the t-shirt. Transfer papers can be stored before heating, allowing for on-demand printing when required, such as for live events or short runs.

Pros

1. Durability: Plastisol transfer prints are known for their longevity, resisting fading and cracking even after multiple washes.
2. Flexibility: The transfer papers can be stored for later use, making it easy to produce t-shirts on-demand.
3. Customisation: Special effects like textures, glosses, and other finishes can be applied to the transfer designs for a unique look.
4. High-Quality Results: The prints are vibrant, and the colours are rich, providing a premium look.

Cons

1. Preparation Time: The process involves multiple steps and requires skilled technicians, making it time-consuming.
2. Not Ideal for Large Orders: While it’s great for smaller, custom runs, plastisol transfer printing may not be the best choice for bulk orders due to the complexity and setup time involved.
3. Limitations on Design: This method is not suitable for printing detailed photographic images, half-tones, or very fine lines.

Airbrushing for T-shirt Printing

Airbrushing is a creative and manual t-shirt printing technique that uses a spray-painting tool to apply designs onto fabric. This method is ideal for artists who want to add unique, freehand touches to their designs, but it’s not as commonly used for large-scale production due to its manual nature.

While airbrushing provides an artistic touch and is great for custom, small-run designs, its limitations in durability and scalability make it less ideal for large-scale commercial printing.

Process of Airbrushing

1. Stencil Preparation: A stencil is created from a material like felt and temporarily attached to the t-shirt with a light adhesive to keep it in place. Multiple stencils may be used for multi-color designs.
2. Paint Application: The airbrush tool is loaded with paint and connected to an air source. For multi-coloured designs, different paints are used. The t-shirt is placed on a board or easel, and the airbrush applies the paint in layers, with each colour applied separately.
3. Design Touches: After applying the paint, additional manual touches or shading can be added for extra detail and artistic flair.
4. Setting the Design: Once the paint dries, the design is protected using paper, and heat is applied with an iron to set the paint, ensuring the design remains intact.

Pros:

1. Creative Freedom: Offers artists complete control over the design, making it ideal for custom, artistic work.
2. Affordable: Low cost and easy to start, making it accessible for small-scale or DIY projects.
   Unique Results: Allows for custom, one-of-a-kind designs that stand out.

Cons:

1. Limited Durability: The designs are prone to fading and wear over time, making them less suitable for long-term use.
2. Labor-Intensive: Requires significant manual effort, making it inefficient for large orders.
3. Lower Quality: It’s difficult to achieve intricate or highly detailed designs with airbrushing, leading to less sharp results compared to other methods.

How to Choose the Best T-Shirt Printing Method?

Selecting the right t-shirt decoration method depends on several key factors, such as the design complexity, fabric type, order volume, cost, and desired finish. Here’s a breakdown of how to decide which method best suits your needs:

1. Design Complexity

If your design is intricate or includes detailed artwork, Direct-to-Garment (DTG) printing is an excellent choice. DTG allows for high-quality, full-colour prints, including fine details, and works best on cotton fabrics. However, it can be expensive for large batches. For simpler designs, screen printing is often preferred for bulk orders due to its cost-effectiveness and vibrant results, though it may not handle complex artwork as well as DTG.

2. Fabric Compatibility

The fabric of the t-shirt plays a significant role in choosing the printing method. Dye sublimation is perfect for all-over prints on polyester fabrics, as it creates vibrant, durable designs that become part of the fabric itself. If you need a versatile method for various fabrics, Direct-to-Film (DTF) printing works well on both cotton and synthetic materials. Plastisol transfers can also be used across different fabrics, including cotton and polyester, and offer the option of glossy or textured finishes.

3. Order Volume

For large orders, screen printing remains the go-to method due to its efficiency and cost-effectiveness. The setup costs are higher, but it becomes cheaper per unit for large quantities. If you’re working on smaller batches or one-off designs, methods like DTG or vinyl printing may be more suitable despite their higher per-shirt cost.

4. Cost

Cost is a crucial factor in the decision-making process. If you’re working with a tight budget or have a small business, vinyl heat printing is a relatively affordable option, especially for text-based designs like sports jerseys. On the other hand, screen printing offers lower unit costs for larger orders, while DTF and DTG tend to be pricier due to their advanced technology.

5. Durability

Durability is important, especially for designs that need to withstand frequent washing. Embroidery offers incredible durability and a professional finish, making it ideal for logos on workwear or uniforms. Screen printing and plastisol transfers also provide long-lasting results, but methods like airbrushing or vinyl printing may not be as durable for heavy wear.

6. Special Effects

If you want to create unique textures or finishes, some methods allow for creative effects. Plastisol transfers can offer glossy or textured finishes, while airbrushing provides an artistic, hand-crafted feel. Vinyl heat transfers are great for adding dimensional effects, especially for bold designs or lettering.

7. Turnaround Time

Consider how quickly you need the t-shirts. Methods like DTG and vinyl printing can be quick, ideal for fast-turnaround jobs or small orders. In contrast, screen printing may take longer due to its setup process, and plastisol transfer printing requires additional steps such as heat pressing, which can extend the production time.

What printing methods are available with T-Shirt Plus?

T-Shirt Plus offers a variety of high-quality tee printing methods to suit every need, from intricate designs to bulk orders.

Each of the following methods at T-Shirt Plus is designed to meet different needs, whether you’re looking for intricate detail, bulk orders, or high durability. We’ll help you choose the right technique for your design and garment to ensure the best results.

1. Direct-to-Garment (DTG)
2. Direct-to-Film (DTF)
3. Laser Transfer
4. Vinyl Heat Transfers
5. Embroidery
6. Digital Full Colour Transfers
7. Dye Sublimation
8. Screen Printing

What is the best t-shirt printing method?

Each printing method has its advantages depending on the design and production requirements. Direct-to-Garment (DTG) is great for printing detailed, full-colour designs with high durability. Screen printing is ideal for bulk orders due to its cost-effectiveness and long-lasting results. Dye sublimation excels on polyester fabrics, delivering vibrant colours and crisp designs by using a unique heat and dye vaporisation process.

Can I use a regular printer for heat transfer paper?

It’s recommended to use an inkjet or laser printer for heat transfer paper, as these printers provide the best resolution for fabric printing. Regular printers might not achieve the same quality or colour accuracy needed for printing on t-shirts.

What type of paper is used for t-shirt printing?

Various types of transfer paper are used for t-shirt printing, including heat transfer paper, vinyl sheets, sublimation transfer paper, and both light and dark transfer papers. These papers are designed to ensure vibrant colours and smooth application when transferring designs to fabric.te