types of Shirt Printing

Types of Shirt Printing Explained with Real Examples

Shirt printing is more than just stamping ink onto fabric - every method relies on a different combination of chemistry, heat and pressure. Some processes deposit a plasticized ink film that sits on top of fibers, while others chemically bond dyes with the polymer chains inside the fabric. Understanding these mechanisms helps you pick a technique that meets your budget, design requirements and durability expectations.

What Is Shirt Printing?

In textile printing, a design is applied to a shirt using ink or dye that bonds with the fabric. Screen printing forces viscous plastisol inks through a mesh stencil and then cures them at around 160 °C (320 °F) so that the liquid vinyl resin fuses into a durable film. Dye-sublimation prints disperse dyes onto transfer paper and then use high heat to turn the dyes into gas, allowing them to penetrate and bond with polyester fibers rather than sit on top. Other methods like direct-to-garment (DTG), direct-to-film (DTF) and heat-transfer vinyl (HTV) rely on water-based inks or heat-activated adhesives to attach the colorant.

Popular Shirt Printing Methods (Main Comparison Section)

Printing Type Best For Durability Feel on Fabric Cost Process Time
Screen Printing Bulk orders & simple graphics High Smooth / lightly raised $$ (setup cost) Slow setup
DTF (Direct to Film) All fabrics & full-color prints Very high Slight handfeel $$ Fast
Sublimation Polyester fabrics & rigid polymer-coated items Excellent No feel $ Quick
Heat-Transfer Vinyl (HTV) Names, numbers & small runs Moderate Slightly thick $ Moderate
Direct-to-Garment (DTG) Detailed multi-color designs Good Soft $$$ Slow


Screen Printing

  • How it works scientifically: Plastisol inks used in screen printing contain PVC particles and plasticizers suspended in a liquid. The design is created on a mesh screen, and ink is forced through onto the garment. To cure, the printed garment is heated so that the ink liquefies (~46 °C), gels (~57 °C) and finally fully cross-links at about 160 °C (320 °F); this process fuses the plastic resin into a film that sits on top of the fibers. Curing requires enough dwell time and heat transfer so that the temperature reaches the inner ink layer and drives off moisture.
  • Why choose it practically: Screen printing delivers vibrant, opaque colors and is cost-effective when printed in bulk, because the initial setup time (creating screens and mixing inks) spreads over many items. It excels at simple logos or slogans with a limited number of colors. Printphase uses refined plastisol and water-based inks and can produce screens quickly; however, like most screen printers, we recommend it for orders where you need dozens or hundreds of shirts.

DTF (Direct to Film)

  • How it works scientifically: DTF printing uses pigment-based CMYK inks printed onto a PET film, followed by a layer of thermoplastic adhesive powder. The film is then heat-pressed onto the fabric at 300-325 °F (149-163 °C) for 10-15 seconds. During pressing the adhesive melts and flows into the fabric fibers; as it cools it crystallizes, creating a strong bond similar to other heat-activated adhesives. Because the ink sits on the film rather than directly on fabric, no pretreatment is required and prints can be stored until needed.
  • Why choose it practically: DTF works on cotton, polyester, blends and even synthetics like nylon or leather, making it more versatile than sublimation. It also allows full-color gradients and small details on dark fabrics. Printphase specializes in DTF transfers; we offer no minimums and our standard orders ship within 24-48 business hours, which is ideal for small businesses needing on-demand prints. Our variety of finishes (opaque, soft vintage, low-temperature, metallic, 3D puff) means you can match the handfeel and durability to your garment. Transparent pricing and an online uploader simplify ordering, and you can even request a free sample pack to test the quality before committing.

Sublimation

  • How it works scientifically: Disperse dyes are printed onto transfer paper using aqueous inks. When the paper and polyester fabric are run through a heat press or calender at around 375-400 °F (191-204 °C), the dyes sublimate (turn from solid to gas) and diffuse into the polyester; the gas molecules bond with the polymer chains and become part of the fiber. Because the dye embeds rather than coating the surface, the resulting print doesn’t crack or peel and remains wash-fast.
  • Why choose it practically: Sublimation produces photorealistic, vibrant colors with no handfeel because the dye becomes part of the fabric. It is excellent for athletic wear, flags and all-over prints. However, it only works on polyester or polymer-coated substrates. The process is quick and relatively low-cost for small runs, but not viable for cotton garments. Sublimation is also considered eco-friendly because it uses less water and electricity than traditional methods.

Heat-Transfer Vinyl (HTV)

  • How it works scientifically: HTV consists of a colored polyurethane (or occasionally PVC) film coated with a heat-activated adhesive. This adhesive is dry and non-tacky until heated; when you press the vinyl onto a garment, the adhesive layer melts, flows into the fiber interstices and then crystallizes as it cools, creating a strong bond. The vinyl itself remains as a solid layer on top of the fabric.
  • Why choose it practically: HTV is ideal for small runs, names and numbers, and designs with solid colors. You can cut and weed individual letters or shapes, making it popular for sports jerseys and custom merchandise. It requires minimal equipment (a vinyl cutter and a heat press), making it budget-friendly for hobbyists. Because the film sits on top of the fabric, it adds a slightly thicker feel and is less breathable. Some HTV films contain PVC; eco-friendly options use polyurethane and PVC-free adhesives for better flexibility and less environmental impact.

Direct-to-Garment (DTG)

  • How it works scientifically: DTG printers use water-based inks and inkjet technology to spray micro-drops directly onto a garment. The inks absorb into natural fibers (cotton, linen, bamboo) and are then heat-cured to fix the pigments. Modern DTG systems can print high-resolution images because the ink is absorbed into the fibers, creating a soft handfeel and detailed color gradients.
  • Why choose it practically: DTG excels at short runs and complex artwork. There are no screen-setup costs, so you can print one-off garments or test designs easily. Printful’s guide notes that DTG is more cost-effective for low-quantity jobs, while screen printing becomes cheaper for bulk orders. DTG requires pretreatment on dark garments and has a slower print time compared with DTF, and prints may fade faster than plastisol or sublimation on synthetics. It is best suited to natural fibers and on-demand production.

How to Choose the Right Shirt Printing Type

When choosing a printing method, consider the following factors:

  • Fabric type: Cotton or natural fibers work well with screen printing, DTF and DTG. Polyester or polymer-coated items require sublimation to achieve permanent, no-feel prints. HTV works on most fabrics but adds thickness, while DTF bonds to cotton, polyester, blends and synthetics.
  • Budget per print: For large runs, screen printing’s high setup cost is offset by a low per-item cost. DTF and HTV are mid-range and economical for small quantities. DTG is more expensive due to ink and maintenance costs; sublimation is inexpensive but limited to polyester.
  • Design complexity: DTG and DTF handle intricate, full-color artwork easily; screen printing excels at simple, bold graphics. Sublimation offers unlimited colors but only on polyester, while HTV is limited to solid colors unless layering multiple films.
  • Quantity: Screen printing is ideal for bulk orders. DTF and DTG are perfect for on-demand or low-minimum runs; Printphase’s DTF transfers have no minimum quantity and fast turnaround. HTV suits one-offs and customization.
  • Durability: Sublimation and well-cured DTF or screen prints hold up to hundreds of washes. HTV has moderate durability; the vinyl layer can crack with heavy wear. DTG prints are softer but may fade sooner on synthetics.

Which Shirt Printing Method Lasts the Longest?

Shirt Printing Method

Longevity depends on how the ink or dye interacts with the fabric:

  • Sublimation offers the highest wash durability because the dye molecules bond chemically with polyester fibers. The color becomes part of the fabric, so it won’t crack or peel.
  • DTF prints sit on the surface but use a thermoplastic adhesive that melts into the fibers and then crystallizes upon cooling. When properly pressed (10-15 seconds at 149-163 °C), DTF transfers can withstand repeated washing and are comparable in longevity to screen prints.
  • Screen printing durability comes from the cross-linked PVC film formed when plastisol ink is fully cured at around 160 °C. A proper cure ensures the ink resists cracking and peel, but under-cured prints will deteriorate.
  • HTV relies on a heat-activated adhesive film. The bond is strong but remains a separate layer on top of the fabric; repeated stretching or high-heat drying can reduce lifespan. Using polyurethane-based, PVC-free films can improve flexibility and wash-fastness.
  • DTG prints penetrate cotton fibers but are typically the least durable of the methods discussed. They can fade faster on synthetic blends, though quality can be improved with proper pretreatment and curing.

Summary

  • Need bulk orders with simple logos? Choose screen printing. It produces vibrant, durable prints and is the most cost-effective when you need dozens or hundreds of shirts. Use water-based inks for a softer feel and lower environmental impact.
  • Want full-color designs on any fabric with fast turnaround? DTF is the workhorse. Printphase’s DTF transfers have no minimum order, quick shipping and a variety of finishes. They work on cotton, polyester, blends and synthetics, making them ideal for brands with diverse product lines.
  • Printing on polyester or rigid blanks? Sublimation yields permanent, photographic prints with no handfeel. It’s perfect for sports jerseys, leggings and all-over designs but won’t work on cotton.
  • Personalizing names or small runs on a budget? HTV allows you to cut and press vinyl designs without expensive equipment. It’s great for team jerseys and individual customization, though the vinyl layer is thicker than other methods.
  • Need photographic detail on natural fabrics? DTG prints intricate artwork directly onto cotton and other natural fibers. It shines in print-on-demand businesses but costs more per item and may fade faster on synthetic blends.

Frequently Asked Questions

What is the best printing method for cotton T-shirts?

 For natural fibers like cotton, screen printing and DTF produce durable results. Screen printing is ideal for bulk orders with limited colors, while DTF offers full-color graphics with no minimum quantity and quick turnaround. DTG is also an option for detailed one-offs but may cost more per print.

Which shirt printing lasts longest after washing?

Sublimation on polyester and well-cured DTF or screen prints on cotton typically last the longest. Sublimation dyes embed into fibers, while DTF and screen printing rely on cured polymers or adhesives that resist washing.

What’s the difference between DTF and sublimation printing?

DTF prints pigment inks onto a film and uses a melting adhesive to bond the image to any fabric. Sublimation prints disperse dyes onto paper and uses heat to submerge the dye into polyester fibers. DTF works on more fabrics and offers vibrant colors on dark garments; sublimation yields a no-feel finish but is limited to polyester or polymer-coated substrates.

Is screen printing still worth it in 2025?

Yes. Screen printing remains the industry standard for bulk apparel because of its low per-unit cost, color vibrancy and durability. Innovations in water-based and low-VOC inks reduce, and specialty inks like metallic or puff add texture. For smaller quantities or photographic detail, combining screen printing with other methods (e.g., DTF for short runs) gives you flexibility.

Which method gives the softest print feel?

Sublimation has no handfeel because the dye becomes part of the fabric. DTG prints are also soft because water-based inks soak into fibers. Water-based screen prints have a soft feel, whereas DTF and HTV add a slight film on top of the fabric.

Back to blog