DTF vs Screen Printing: Pros, Cons, and When to Use Each

The Great Debate: DTF vs Screen Printing

If you're ordering custom printed apparel, you've likely encountered both DTF (Direct-to-Film) and screen printing. Both produce professional results, but they work very differently. This guide breaks down everything you need to know to make the right choice for your project.

How Screen Printing Works

Screen printing is the traditional method that's been around for over a century. Here's the process:

  1. A mesh screen is coated with light-sensitive emulsion
  2. Your design is burned into the screen using UV light
  3. Ink is pushed through the screen onto the fabric
  4. Each color requires a separate screen
  5. The ink is cured with heat

How DTF Printing Works

DTF is a newer technology that uses a different approach:

  1. Design is printed in full color onto special PET film
  2. Adhesive powder is applied and cured
  3. The transfer is heat pressed onto the garment
  4. Film is peeled away, leaving the design

Head-to-Head Comparison

Color Capability

Screen Printing: Each color requires a separate screen. Most shops limit designs to 1-6 colors to keep costs reasonable. Gradients and photographic images are difficult or impossible.

DTF: Unlimited colors at no extra cost. Full photographic prints, gradients, shadows, and complex artwork all print beautifully.

Winner: DTF

Setup Costs

Screen Printing: Requires screen creation for each design and color. Setup fees typically run $25-50 per screen, meaning a 4-color design costs $100-200 just in setup before any shirts are printed.

DTF: No setup fees. Your design goes straight from file to film.

Winner: DTF

Minimum Orders

Screen Printing: Due to setup costs, most shops require minimums of 12-24 pieces to make it cost-effective.

DTF: No minimums. Order one shirt or one thousand - the per-piece price stays consistent.

Winner: DTF

Fabric Compatibility

Screen Printing: Works best on 100% cotton. Polyester requires special inks that add cost. Some fabrics are incompatible entirely.

DTF: Works on cotton, polyester, blends, nylon, leather, and more. The adhesive bonds with virtually any fabric.

Winner: DTF

Bulk Pricing

Screen Printing: Cost per piece drops dramatically at high volumes. 500+ pieces can be cheaper than DTF due to minimal ink costs once setup is complete.

DTF: Cost per piece stays relatively flat. Good value at any quantity, but doesn't scale as dramatically.

Winner: Screen Printing (at 200+ pieces)

Print Feel

Screen Printing: Ink sits on top of fabric. Can feel thick, especially with multiple colors or white underbase. Water-based inks offer softer hand feel but cost more.

DTF: Thin, flexible transfer that moves with the fabric. Soft hand feel similar to the garment itself.

Winner: DTF

Durability

Screen Printing: Extremely durable. Properly cured plastisol ink can last the life of the garment.

DTF: Very durable - 50+ washes with proper application. Slightly less longevity than screen printing in extreme conditions.

Winner: Screen Printing (slightly)

Turnaround Time

Screen Printing: 5-10 business days typical due to screen creation and setup time.

DTF: Same-day to 2-3 days. No setup means faster production.

Winner: DTF

When to Choose Screen Printing

  • Ordering 200+ pieces of the same design
  • Simple 1-3 color designs
  • Need maximum durability for workwear
  • Printing on 100% cotton only
  • Large corporate orders with long lead times

When to Choose DTF

  • Ordering 1-200 pieces
  • Full-color, photographic, or gradient designs
  • Printing on polyester, blends, or specialty fabrics
  • Need fast turnaround
  • Testing new designs before committing to bulk
  • Small business with varied inventory
  • One-off custom orders

The Verdict

For most small businesses, events, and personal projects, DTF is the clear winner. It offers more flexibility, faster turnaround, no minimums, and better results on a wider range of fabrics.

Screen printing still makes sense for large corporate orders where you're printing thousands of the same simple design on cotton shirts.

DTF Printing in Jacksonville NC

At Mabuhay Designs & Co, we specialize in DTF printing for Jacksonville NC and surrounding areas. Whether you need one custom shirt or transfers for your entire business, we deliver professional results with same-day service available.

Not sure which method is right for your project? Contact us at (910) 757-7596 for a free consultation. We'll help you make the best choice for your specific needs and budget.

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