Screen Printing vs DTG: Best for Custom T-Shirts?
Screen printing quotes catch first-time buyers off guard: a 3-colour design on 12 shirts can cost more per unit than ordering 200. For small runs of custom t-shirts, the print method you choose directly controls whether you break even or overspend.
What Screen Printing Actually Is
Screen printing pushes thick ink through a mesh stencil directly onto the fabric. Each colour in your design needs a separate screen. UK print shops charge roughly £25 to £45 per screen to produce, so a 4-colour logo adds £100 to £180 in setup costs before a single shirt is printed.
Spread that across 100 Gildan Heavy Cotton T-Shirts and the setup cost adds under £2 per unit. Spread it across 12 shirts and it is closer to £15 extra per piece. The ink is vivid and sits on top of the fabric. A properly cured screen print survives 50 machine washes without cracking or fading noticeably.
What DTG (Direct-to-Garment) Is
DTG fires water-based ink directly onto the garment using a modified inkjet head. No screens, no setup fee. A single full-colour front print at a UK shop typically runs £8 to £14 per shirt in 2026. Order one shirt. Switch colours between units. Print a 15-shade gradient at no extra cost.
Dark garments need a white underbase layer first, which adds roughly £1.50 to £3 per piece and slightly softens the hand feel. Lightweight blanks such as the Gildan Softstyle T-Shirt take the underbase well because the thinner fabric absorbs it without stiffening.
Side-by-Side
| Factor | Screen Printing | DTG |
|---|---|---|
| Setup cost | £25-45 per colour | None |
| Best order size | 50+ units | 1-30 units |
| Colour complexity | 1-6 spot colours | Unlimited, photographic |
| Wash durability | Excellent | Good with correct pre-treatment |
| Cost per unit (100 shirts) | £3-6 | £8-14 |
Does the Same Rule Apply to Custom Hoodies?
Yes. The decision works the same way for custom hoodies. A Fruit of the Loom Classic Hooded Sweatshirt is a standard blank for both methods. Under 30 units with a multi-colour back print, DTG wins on price. Over 50 units with a 2-colour chest logo, screen printing is cheaper per piece by a clear margin.
Heat-transfer vinyl (HTV) is a third option worth knowing about. For a single name or number on a sports kit, it beats both methods on turnaround. A single-colour text print via HTV takes minutes to produce. It is not suited to full-chest photographic work, but for simple lettering it is the fastest option available.
FAQ
What is the minimum order for screen printing in the UK?
Most UK screen printers set a minimum of 12 to 25 units per design. Below that, the setup cost per shirt makes the job uneconomical for the printer. A handful of specialist shops will accept runs of 6, but expect a premium price.
Is DTG printing as durable as screen printing?
With proper pre-treatment and curing, DTG prints hold up well and typically last 30 to 50 washes before noticeable fading. Screen printing edges ahead on raw durability, particularly for white ink on dark garments after repeated washing.
Can I print a photograph on a custom t-shirt?
Yes. DTG handles photographic detail and smooth gradients with no extra charge. Screen printing can approximate photos using a halftone technique, but it loses fine detail and requires skilled colour separation work. For photo-quality results, DTG is the practical choice.
How long does DTG printing take?
A standard DTG order of 10 to 20 shirts takes 2 to 5 working days at most UK print shops in 2026. Rush 24-hour turnaround is available at a surcharge from some suppliers.
Which method works best for a streetwear drop?
For limited drops of under 30 units per colourway, DTG is the go-to. It lets you test multiple designs with no overstock risk. Once a design proves popular and you are ordering 50 or more, moving to screen printing cuts your cost per unit significantly.