Screen Print vs DTG: Best Method for Custom Tees
Most first-time buyers pay 35-45% more than necessary by using DTG for bulk orders. Order count is the deciding factor, and the maths is simple.
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The Core Difference
Screen printing forces ink through a mesh stencil onto fabric. Each colour requires a separate screen, and setup costs run £15-40 per colour. That sounds steep until your order clears 30 shirts, at which point the per-unit price drops to roughly £3-6 for a two-colour design.
DTG (direct-to-garment) printing works like an inkjet aimed at fabric. No screens, no setup charges. Whether you print 1 shirt or 100, the machine cost per unit stays roughly flat at around £8-12 per shirt at most UK print shops.
When Screen Printing Wins
Streetwear drops, sports kits, and promotional orders of 30 or more all suit screen printing well. Plastisol ink bonds tightly with cotton, and a correctly cured print typically survives 50 or more washes without cracking. A blank like the Gildan Heavy Cotton T-Shirt holds screen ink cleanly and keeps your blank cost low enough that the overall numbers stay attractive. Spot colours on cotton pop in a way that budget DTG printers rarely match.
When DTG Wins
Suppose you need 12 personalised hoodies, each with a different name. Screen printing requires a new screen per variation; DTG prints each piece individually at no extra setup cost. It also handles photographic artwork, ten-colour gradients, and fine illustrative detail that would cost a fortune to separate and screen print. For micro-batch drops, an AWDis Just Hoods College Hoodie printed via DTG delivers professional results without committing to bulk stock.
One caveat: DTG on dark garments needs a white underbase layer first, adding roughly £1-2 per shirt and sometimes making the print feel thicker. On white or pale fabric, colour accuracy is excellent.
A Quick Cost Comparison
At 10 shirts, DTG runs approximately £90-120 total; screen printing setup fees alone would reach £60-120 before a single shirt is printed. At 50 shirts with two colours, screen printing brings the total to roughly £200-280; DTG at the same volume costs £400-600. The crossover point sits at around 24-28 shirts for a typical two-colour design.
Making the Right Call
Under 20 pieces or complex multi-colour artwork: DTG. Over 30 pieces with bold, simple spot colours: screen print. If your design has six or more ink colours and you are ordering fewer than 75 shirts, get a quote for both before committing. Quality blanks matter for both processes. The Bella+Canvas Unisex Jersey T-Shirt is a firm favourite across UK streetwear labels for its softness and consistent print surface on both methods.
TMK Tees offers both screen printing and DTG. Upload your artwork at tmktees.com and get live pricing for your exact run size.
FAQ
What is the minimum order for screen printing in the UK?
Most UK screen printers set a minimum of 12-24 shirts per design. Below that threshold, setup costs push the price per shirt above what DTG charges. For runs under 12 pieces, DTG is almost always the more cost-effective option.
Can DTG printing be used on dark-coloured shirts?
Yes, but a white underbase layer is printed first to stop dark fabric absorbing the colours. This adds roughly £1-2 per garment and can make the printed area feel slightly thicker. Screen printing on dark fabric uses high-opacity inks and often produces a sharper edge, especially on black garments.
How many washes does a screen print survive compared to DTG?
A correctly cured plastisol screen print typically holds for 50-80 wash cycles before noticeable fading begins. Washing inside-out on a 30-degree cycle extends that significantly. DTG prints on pre-treated fabric generally last 30-50 washes under the same care conditions.
Which method is better for launching a streetwear brand?
For a first drop of 50-100 pieces, screen printing gives you lower unit costs and sharper spot-colour results on cotton blanks. If your designs vary per piece, or you want to sample before committing, DTG lets you test ideas without buying bulk stock. Many independent labels use DTG to sample, then move to screen printing once a design sells consistently.
What file format do I need to send for custom tee printing?
For screen printing, send a vector file (AI or EPS) with fonts outlined. For DTG, a high-resolution PNG at 300 dpi or above at print size, with a transparent background, is the standard. JPEG files are accepted but can introduce edge artefacts, particularly on fine details and text.