FREQUENTLY ASKED QUESTIONS

Screen printing (also called silkscreen or serigraphy) transfers ink through a fine mesh screen onto a “substrate” such as fabric, paper, plastic, metal, or glass. Parts of the mesh are blocked with a stencil so ink only passes where the design should appear.

Core idea of each

• Screen printing: Ink is pushed through a mesh stencil onto the garment, one screen per color. Great for solid, bold designs and bulk runs.

• DTG (Direct to Garment): A digital printer sprays water-based ink directly into the fabric, like an inkjet on a shirt. Ideal for detailed, full‑color artwork and small runs.

• DTF (Direct to Film): A printer prints the design onto a special film, adds adhesive powder, then a heat press transfers that film to the garment. Very versatile across fabrics and colors.

• Vinyl (HTV): A plotter cuts shapes/letters from colored vinyl sheets, which are then heat‑pressed onto the garment. Best for simple graphics, names, and numbers.

• Embroidery: A machine stitches the design using thread directly into the fabric. Premium, textured look, great for logos, hats, polos, and thicker garments.

How they differ in practice

• Detail and color range:

  • DTG and DTF handle complex, photographic, and many‑color designs best.

  • Screen printing can do detail, but each color adds cost; halftones are more technical.

  • Vinyl is limited to solid shapes and spot colors.

  • Embroidery has the lowest design resolution (thread thickness limits fine detail).

• Feel on the garment (hand feel):

  • DTG usually feels soft because ink soaks into the fibers.

  • Screen printing can feel slightly raised or smooth, depending on ink type and deposit thickness.

  • DTF and vinyl feel like a film on top of the fabric (more “sticker‑like” for cheap DTF or thick vinyl).

  • Embroidery is fully raised and textured, with backing on the inside of the garment.

Durability and wash

• Most durable overall: high‑quality screen printing, DTF, and embroidery if done correctly.

• DTG can be durable but tends to fade sooner than good plastisol or DTF on heavy use and aggressive washing.

• Vinyl is generally very durable but can crack or peel if poorly applied or overheated.

Order size and cost structure

• Screen printing:

  • High setup cost (screens, separations), very low cost per piece at scale.

  • Best for medium–large runs with limited colors.

• DTG:

  • Little to no setup cost, higher cost per piece.

  • Best for one‑offs, small batches, on‑demand printing.

• DTF:

  • Moderate setup per design, good for short to mid‑size runs, especially with many colors.

  • Transfers can be printed in bulk and applied later, useful for flexible production.

• Vinyl:

  • Low setup but labor‑intensive for complex designs.

  • Great for names, numbers, and very small runs with simple art.

• Embroidery:

  • Setup cost in digitizing the logo, then cost is driven by stitch count and time.

  • Best for smaller logos and mid‑size runs where perceived value is important.

Fabric and use‑case fit

• Screen printing: Very good on cotton and blends; with the right inks, also on polyester, performance wear, bags, etc.

• DTG: Performs best on high‑cotton content garments; struggles more on some synthetics.

• DTF: Very flexible across cotton, blends, polyester, and even some hard goods.

• Vinyl: Works on most fabrics that can handle heat pressing; widely used for sports jerseys and workwear.

• Embroidery: Best on stable, thicker fabrics (polos, hats, jackets, beanies); can distort very thin or stretchy garments.

Common apparel items

Screen printing is most popular on casualwear made from cotton or cotton‑rich blends, because those fabrics accept ink well and cure reliably. Typical printable garments include:

• T‑shirts and long‑sleeve tees (100% cotton, cotton‑poly, tri‑blends)

• Hoodies, crewneck sweatshirts, and joggers (fleece, French terry, cotton blends)

• Tank tops, crop tops, and fashion tees (including lightweight and tri‑blend fabrics)

With appropriate inks and process control, printers also decorate performance and team‑sports items like polyester jerseys and gym wear, though they must manage dye migration and heat carefully.

Bags, totes, and soft accessories

Many shops screen print on heavier cotton and canvas items because the flat, sturdy surfaces give crisp results and hold up well to use.

• Tote bags, grocery bags, and drawstring bags (cotton, canvas, non‑woven polypropylene)

• Backpacks and duffel bags with printable panels

• Aprons, bandanas, and fabric banners or flags

Heavier canvas (for premium totes or utility bags) usually takes bold, simple graphics best, while smoother, lighter fabrics can hold finer detail.

Headwear and outerwear

Certain hats and outerwear can also be screen printed if there is a relatively flat, reachable area.

• Beanies and knit caps (often with simple logos)

• Some flat‑front caps, bucket hats, and visors (if the crown or bill can be pressed flat)

• Light jackets, windbreakers, and workwear with print‑ready panels, often made from cotton, nylon, or polyester blends.

Very textured or highly structured areas, like thick seams or heavily curved hat panels, are often better suited to embroidery or transfers rather than direct screen printing.

Specialty textiles and promotional items

With the right inks and mesh, screen printing also extends beyond apparel into general promotional products.

• Fabric products such as tea towels, pillow covers, tablecloths, and fabric wall hangings

• Packaging items like cotton or canvas gift bags and cosmetic pouches

• Some non‑fabric items (e.g., certain plastics, paper, cardboard, and treated wood) using specialty inks and appropriate curing methods.

Very fuzzy, highly textured, or heat‑sensitive materials (e.g., thick faux fur, some stretchy blends, or delicate silks) are more challenging and may require modified techniques or different decoration methods.