10 Different Types of Shirt Printing - Complete Guide

10 Different Types of Shirt Printing - Complete Guide

Choosing the right printing method is crucial when creating custom t-shirts, as it impacts the design quality and longevity. Understanding each method is essential to picking the best way to print on shirts for your needs. In this guide, we’ll explore 10 different types of shirt printing methods, highlighting their benefits and the associated processes.

10 Different Types of Shirt Printing

types of shirt printing

1. Screen Printing (Silkscreen)

Also known as silkscreen printing, screen printing is one of the oldest and most common methods of printing shirts. In screen printing, a stencil is created on a fine mesh screen. A squeegee is then used to push ink through the mesh onto the fabric. Once a stencil is created on the screen, the printer applies pressure to push the ink through the designated areas and transfer the design onto the apparel.

Process and Method

The process of screen printing utilizes a different screen for each color in the design. A mesh is coated with a light-sensitive emulsion and exposed to your artwork. After you wash away the unexposed areas, you will have your stencil. Although the individual steps may seem tedious, this is ideal for shirt printing businesses because you can print numerous shirts on the same screen printing process at once.

Advantages and Limitations

Benefits:

  • Superior durability and color vibrancy
  • A good method for low-cost bulk printing
  • Can be used with numerous fabric weights
  • Good for repeated consistency across numerous prints

Drawbacks:

  • Significant setup for small quantities
  • No gradients of colors
  • Setup is generally time-consuming

Fabric Compatibility

Fabrics, including cotton, silk, and wool, all react well with screen printing inks. Cotton is the fabric of choice because of its highly smooth surface, beautiful ink absorption characteristics, and long-lasting print after being washed multiple times.

2. Direct-to-Garment (DTG) Printing

Direct-to-garment printing has changed the world of customizing shirts. It acts like a large inkjet printer made for fabrics. Rather than the process of screen printing, direct-to-garment technology sprays water-based inks directly onto fabrics with unique printing heads for visibility and detail.

How does DTG printing work?

  • Pretreating: Treat fabric with a special solution to help the inks stick.
  • Digital Printing: Printing the fabric design directly with great digital printing technology.
  • Heat Cure: The printed design gets heat cured; this helps the ink stick permanently and makes it washable.

The Benefits of DTG Printing

  • DTG printing has many benefits in comparison to other methods of printing:
  • Unlimited Color Variability: DTG printing can basically reproduce whatever color you need at no additional charge, and it does not require a separate setup for each color like screen printing.
  • Photo-Realistic Quality, ty: DTG printing is great for complex artwork and designs with color gradients, as it is able to produce more detail and realism than other printing methods.
  • No Minimum Orders Requirement: DTG is great for people and small shops that want custom shirts, especially in small quantities, and since there are no minimums, it allows for greater creativity.
  • Soft Hand: DTG inks penetrate the fabric fibers, providing an overall softer feel without compromising comfort or functionality as opposed to other printing methods

The Disadvantages of DTG Printing:

Despite the advantages of DTG printing, there are some drawbacks:

  • Production rates: While fast and easy for customers to make custom shirts, DTG printing can be hassle-free for small-to-medium orders compared to screen printing or heat transfer vinyl (HTV).
  • DTG Printing needs to be put on fabric that will absorb the inks effectively. 
  • Although all types of paper can be printed, DTG is very particular about what fabrics can be printed on. Cotton and other natural fibers are the recommended substrates for DTG Printing. When using synthetic materials, the inks do not successfully absorb, resulting in an undesirable print.
  • Dark garments: When printing on dark materials, DTG printers require an additional white underbase layer printed to achieve bright colors. Otherwise, to use a true color like red or yellow, more ink and the process becomes harder and a bigger ordeal.

When to Use DTG Printing

DTG printing is a cost-effective option for orders of 50 pieces or under, especially where the designs are complex and would require multiple screens with traditional printing methods. Take a look at the following scenarios where you might want to use DTG:

  • You are a small business or a startup looking to get custom shirts for promotional purposes.
  • You are an artist or designer who wants to print your artwork on apparel to get noticed.
  • You want to make custom gifts, like t-shirts for weddings and gifts for guests at conferences.

Knowing the advantages and disadvantages of different printing methods, including DTG, will help you decide and plan how best you can deliver your creative ideas and work within your budget.

3. Direct-to-Film (DTF) Printing

DTF printing (direct-to-film) is a new shirt printing method that uses the latest transfer technology to create amazing results. When developing products using DTF printing, designs are printed onto a special PET film using water-based inks. After the design is printed, the DTF process requires a hot-melt adhesive powder, which is applied to the design, heated to create a bond to the film using heat. 

The transfer process involves a heat press to transfer the film-printed design directly on the fabric to create a permanent bond using heat and pressure. The DTF printing method is a great fabric printing option and offers great flexibility in terms of fabric types.

Key Benefits of DTF Printing:

  • Unlimited color reproduction with photographic quality
  • Fabric flexibility - use cotton, polyester, fleece, and nylon blends
  • Retain fine detail much better than traditional processes 
  • No fabric pretreatment necessary 
  • Soft hand feel after application

Disadvantages:

  • Equipment costs are higher initially 
  • Uses specialized films and adhesive powders 
  • Labor-intensive process for larger orders 
  • Learning curve for getting the best possible printing results

Best Practices for DTF Printing:

If you want to get good results from DTF printing, then you should also observe the best practices. Below are some of the best practices to keep in mind: maintain a consistent heat press temperature of 160-170°C, maintain firm pressure for 15-20 seconds on the heat press, and use good-quality PET films that offer vivid and long-lasting prints. For a detailed overview of the best practices for DTF printing, refer to this resource.

4. Heat Transfer Vinyl (HTV) Printing

Using heat transfer vinyl (HTV) printing, you can create your own custom designs from colored vinyl sheets by cutting down and applying heat to the vinyl. This process requires specialized cutting machines to create shapes, letters, and/or images from vinyl material, which you then apply with heat-press equipment using a heat press at designated temperatures typically between 300-320 degrees Fahrenheit.

HTV shirts have some significant advantages for specific uses:

  • Long-lasting durability: The vinyl adheres permanently to the fabric fibers, making the design last through multiple washes
  • Precision: The cutting produces clean, crisp edges, great for text and simple graphics
  • Cost to produce: Mi: mal costs to set up, making it ideal for small batches
  • Fast production: No drying time means you can produce it right away

The medium does have limitations that you should consider. As the designs get larger, there are costs associated with the vinyl to produce them, which are fairly high, and for more complex/elaborate artwork that involves multiple colors, it will require layering different vinyl pieces.

Typical applications are for sport jerseys with player names and numbers, corporate uniforms with logos, or apparel with an individual name or names. It is relatively simple if you have a bold, uncomplicated, empty design with solid colors to apply to cotton and polyester blend fabrics that can be heat-pressed at high heat.

Also Read: Types of Logo for Apparel Printing with Pros & Cons

5. Dye Sublimation Printing

Dye sublimation printing is a unique, long-lasting process for taking digital images and converting the image into amazing, permanent art through a chemical process. To describe in detail the dye sublimation printing process, a good read is this Wikipedia article. In sum, for the dy sublimation printing process, you first have to take your design or image and print it on a very specially designed heat transfer paper with sublimation inks. The sublimation ink is heated to approximately 400°F (204°C) under pressure. This is the best example of skipping the liquid phase. The sublimation inks do not become liquid; sublimation inks go from solid directly to gas, or sublimation. Once sublimated, the gases are sucked into the synthetic fibers and bond with the fabric throughout the entire thickness of the polyester or polyester-blend. The result is a printed shirt that doesn't fade and is permanent.

Sublimation shirts (made with dye sublimation printing) are made in polyester or in polyester mixes. That is to say, polyester shirts, or made from polyester blend fabric, are used because, as explained here, synthetic fibers have a molecular structure compatible with the inks used in the sublimation process. This key restriction is pronounced asse, for instance,ce in working on athletic wear, activewear, and performance fabrics.

Benefits of Dye Sublimation:

  • Full range of printing across an entire garment
  • Unlimited colors with photo-realistic quality
  • Does not crack, peel, or wash away
  • Breathable result that does not feel like any other type of print on the fabric

Drawbacks:

  • Can only be used with synthetic fabrics
  • Higher preparation costs for smaller quantities
  • Requires specialized printing equipment and papers
  • White or lighter colored garments provide the best results

6. Plastisol Transfers

Plastisol transfers represent a unique hybrid combining the screen printing and direct heat application method. Plastisol transfers carry the durability of screen printing while using the methods of a heat press.

How it works:

To produce a plastisol transfer to be applied to your fabric surface, you print your design using plastisol ink on release paper. When you are ready to apply your transfer, you will use a heat press at around 350-375°F for 10-15 seconds. The heat from the heat press activates the plastisol ink and bonds it permanently to the fabric fibers while removing the release paper cleanly at the same time.

Benefits of Plastisol Transfers

  • Very durable: They have the same durability as conventional screen printing.
  • Great for on-demand printing: This would be great for live events.
  • Managed well on challenging material: They work well on fleece and performance textiles.
  • Inventory control: You can manage your inventory as you do not have to pre-print any garments.
  • They have great vibrancy: Opacity on dark material, plastisol transfers will create vibrant colors.

Limitations of Plastisol Transfers

  • Cost-effective for large orders: Plastisol transfers are less effective than direct screen printing only when ordering higher quantities due to their higher per-unit cost.
  • Equipment: You will need a heat press. You will also need to be able to control the heat and time.
  • Space: Designs must fit within the size of the transfer paper used, as this method does not provide full-coverage printing (or not effectively)

This technique is extremely valuable for sports teams, promotional events, or even companies that need to manage inventories that are flexible inventories.

7. Embroidery

Embroidery on shirts is a great option for your printing needs and a nice alternative to ink printing. With embroidery, you are stitching directly onto the fabric with colored threads instead of using ink to print onto the fabric. Embroidery has been used for centuries, and creates three-dimensional raised designs directly stitched to the fabric instead of two-dimensional prints, utilizing precision stitching and stitching of threads to draw visual depth.

How Embroidery Works

Embroidery starts with your design being digitized to be machine-readable form. The machine then uses the thread's color/design to stitch your design. The embroidered design, will have character and depth that standard printing cannot achieve, because of the various ways the threads can be arranged to create your design - three-dimensional stitched garments will have character and depth even if you use many standard stitch types such a satin stitches for solid fills, running stitches for outlines, and fill stitches for sections are some choice in stitches, and finding what will lead to the desired effect.

Benefits of Embroidery

  • Unparalleled durability, can withstand repeated washes
  • Professional and upscale appearance ideal for corporate branding
  • Works well on cotton t-shirts, polo shirts, and hoodies
  • Results in a tactile three-dimensional effect

Limitations of Embroidery

  • The per-piece cost is higher than other printing methods
  • Design can be restricted by thread types
  • More time-consuming for branding with additional detail on the design.
  • Color gradients and photographic reproduction won't work with embroidery.

Embroidery is particularly useful for logos, monograms, and simple art where the finished product is to have a premium finish that brings forth quality and attention to detail without the brashness.

8. Discharge Printing

Discharge printing is a technique of printing shirts that has taken the concept of traditional shirt printing and flipped it on its head. Discharge printing works by removing existing dye rather than adding colors to a garment. This process allows for a much softer feel, as the dye is completely removed and real replacement pigments are added.

To achieve this look, a special agent is applied to the fabric to break down the dye molecules in a particular area of the shirt, leaving lighter areas to represent your design. You usually see discharge printing utilized on dark colored cotton shirts, where the discharged areas will become visible by the contrasting tones in the original fabric color.

The positive aspects of discharge printing are:

  • Very soft hand feel - no texture on the fabric; 
  • The vintage, worn-in look is desirable to many. 
  • The durability is excellent, since it is part of the fabric. 
  • Nothing will crack or peel.

Discharge printing requires some consideration with:

  • Only cotton or cotton blend and associated types; 
  • Only works on dark shirts. 
  • Color results vary depending upon fiber and original dye chemistry. 
  • Requires special chemicals and safety equipment;

This technique is excellent for doing medium-to-large runs with the authentic look and feel that consumers love.

Also Read: 5 Types of Shirt Printing for High-Quality Custom Apparel

9. Airbrushing

Airbrushing shirt painting is the most artistic way to print on t-shirts of all techniques. For this process, artistically trained individuals take your shirt garment and turn it into the canvas or substrate, using airbrushing tools and special fabric paint or acrylics.

How Airbrushing Works

Airbrushing takes a considerable amount of manual skill and artistic talent. Artists control the flow of paint, how much air pressure they use, and the way they spray to create effects, including gradients, shadows, and fine details that digital printing is incapable of doing. You have the option to request completely custom artwork, portraits, landscapes, or abstract designs that represent your style.

Important Characteristics of Airbrushing:

  • Totally artistic freedom: There are no design restrictions or color restrictions.
  • Hand-painted original: Every piece becomes an original piece of art.
  • Labor-intensive: It requires skilled artists and lots of time.
  • Expensive: Higher costs are the result of manual labor and artistry.
  • Not durable: Applied paint will fade/crack with repeated washing.

When to Use Airbrushing:

Airbrushing is the best option when you need a one-of-a-kind piece rather than mass production. The nature of air-brushing makes it hard to do a bulk project, but it is a great option for special occasions, personalized gifts, or wearable art pieces.

10. Heat Transfer Paper Printing:

Heat transfer paper printing is a flexible way to jump into a custom shirt-making business, and it can even be done at home or small workshop. Heat transfer paper printing gives you the ability to make heat transfer paper shirts right in your own home or in a small workshop. The process of heat transfer printing simply involves putting your design onto a paper transfer paper (with either an ink jet or laser printer) and then using heat to activate the design onto fabric. 

Heat transfer printing can require very little equipment - transfer paper and either an iron at home or a heat press machine. You only need to print your design onto the special transfer paper in reverse (mirror image), lay it on the desired garment, then heat and pressure it for the required time. The heat causes the adhesive backing to make a permanent bond to the desired fabric.

Main Features of Heat Transfer Paper Printing:

  • Affordable option suitable for small quantities and one-off jobs
  • Quick turnaround with instant results
  • DIY - everything you need is fairly accessible 
  • Less durable/fading in comparison to professional methods."
  • Best results on cotton/cotton-blend fabrics
  • Good for personal use, small start-ups, and prototypes

Best for text-based designs, simple graphics, and you want to make a few custom shirts, but don't want to spend lots of money on equipment or have to meet a minimum order quantity.

FAQs (Frequently Asked Questions)

1. What are the main types of shirt printing methods covered in the complete guide?

Guide takes you through 10 different types of shirt printing methods: screen printing (silkscreen), direct-to-garden printing (DTG), Direct-to-Film Printing (DTF), Heat Transfer Vinyl Printing (HTV), HTV submission, dye submission printing, dye submission, plastictransferringg, embroidery, embroidery. Airbrush, Heat Transfer Paper.

2. How does screen printing work and what fabrics is it best suited for?

The screen printing applies ink to the fabric via mesh screens and stencils. This method is best suited for bulk shirt printing in lively colors. Recommended clothes for screen printing include: cotton, silk, and wool. This is the most economical option for large orders, although it cannot work best for complex designs.

3. What are the advantages of Direct-to-Garment (DTG) printing for custom shirts?

Using water-based ink like DTG printing, the inkjet technique applies ink directly to the fabric, yielding complex and photorealistic designs. Its use on DTG works best on 100% cotton or cotton mixtures. DTG printing is best for small runs and wide artifacts or designs that are wide.

4. When should I choose Direct-to-Film (DTF) printing over other methods?

DTF printing is a method that works best for clothing and other fabric-based products. It applies a picture from a pet film using a heat press. DTF printing is known to produce complex, small, vibrant prints in infinite colors.

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