DTF vs. Screen Printing: Which Custom T-Shirt Method is Right for You?

When it comes to custom t-shirt printing, Direct-to-Film (DTF) and screen printing are two of the most popular methods available, each offering unique benefits and capabilities. 

DTF printing is known for its versatility and ability to produce vibrant prints and intricate detail, even on dark fabrics. On the other hand, screen printing is a tried-and-true method, used for its durability. 

Whether you’re running a small print shop, managing a large business, or pursuing a creative hobby, understanding the differences between these two techniques can help you choose the right printing method for your project. In this blog, we’ll break down the processes, costs, and benefits of DTF vs. screen printing and help you make an informed decision on the best supplies for your specific needs — available right here at Atlanta Vinyl.

Printing Process

DTF Deep Dive

Direct-to-film (DTF) printing is a modern method that uses a film transfer process to create detailed, high-quality designs. Here’s how it works:

1. Prepare Your Artwork: The first step is to prepare your design using software like our custom DTF transfer design feature. 
2. Print the Design onto Film: A special printer (typically a modified inkjet printer) is used to print your design onto transparent film with water-based, pigmented inks.
3. Apply Adhesive Powder: While the ink is still wet, a hot-melt adhesive powder is sprinkled over the design. This powder ensures the design will stick to your fabric later.
4. Cure the Film: The film is gently heated to cure the ink and melt the adhesive powder, bonding the two layers together.
5. Transfer the Design: Using a heat press, the prepared film is pressed onto your fabric. The heat activates the adhesive, permanently securing the design. Once cooled, the film is peeled away, leaving the print behind.

DTF printing is easy to learn, requires less setup, and works on a variety of materials, making it perfect for small print runs or detailed, full-color designs.

Screen Printing Overview

Screen printing is a more traditional method that involves creating a stencil to transfer ink directly onto the fabric. Here’s a step-by-step overview:

 

1. Prepare the Screen: You’ll be using a screen that is made from a frame that holds a tightly stretched, fine mesh material, typically made from polyester or nylon
2. Apply Emulsion: A light-sensitive emulsion is applied to the mesh screen to block ink in certain areas.
3. Expose the Screen to Light: The artwork is placed on the screen, and it’s exposed to a light source. The light hardens the emulsion in exposed areas, while the covered areas remain soft.
4. Wash Out the Stencil: The screen is rinsed, washing away the soft emulsion and leaving a stencil of the design.
5. Print the Design: Ink is pushed through the stencil onto the fabric using a squeegee. Each color in the design requires a separate screen, and the colors are layered one by one.
6. Cure the Ink: Once the design is printed, the ink is cured using a heat source to ensure it bonds with the fabric and stays durable over time.

Screen prints are ideal for simple designs with limited colors, but it require more setup time and effort compared to DTF.

 

Printing Cost Comparison

DTF Cost: Low Cost, Easy Set Up! 

DTF printing has a relatively low setup cost, making it a budget-friendly option for projects and on-off prints. Since you don’t need to create separate stencils or screens, you can print multiple designs without significant additional expenses. This flexibility allows you to handle custom orders more cost-effectively.

However, for large-scale production, the cost per print might be higher compared to screen printing due to the time it takes to prepare and press each transfer. DTF shines when producing vibrant colors, detailed designs in smaller quantities or when personalizing items.

Screen Printing Cost: Higher Cost, Simple Designs.

Screen printing has higher upfront costs, primarily due to the need to create screens for each color in the design. The process of preparing screens and setting up the press takes time and materials, making it less economical for short runs or individual prints.

That said, once the screens are set up, printing each item can be relatively quick and efficient. For larger projects with simpler designs, screen printing is sometimes preferred.

Printing Design Complexity

DTF: Easy to Do! 

DTF printing is a standout choice when it comes to intricate and detailed designs. It excels at handling complex artwork, including fine lines, gradients, and full-color images. With DTF, there’s no limit to the number of colors you can use in a design, making it perfect for photorealistic, vibrant prints.

Additionally, DTF printing allows for precise detail, making it ideal for logos, artwork with small text, or designs with shading and texture. Whether you’re creating eye-catching graphics or unique one-off pieces, DTF delivers impressive results without compromising on quality.

Screen Printing: Somewhat Labor-Intensive

Screen printing is best suited for simpler designs with bold lines and fewer colors. Since each color in a design requires its own screen, multi-color designs can become labor-intensive and costly to produce. Complex patterns, gradients, or highly detailed images may not translate well using this method.

However, for designs with one to three colors, screen printing offers exceptional clarity and vibrancy. It’s a great option for logos, basic graphics, or large-scale runs where simplicity is key.

Durability and Feel

DTF: Durable 

DTF prints are highly durable prints, resisting cracking and fading. However, the printed area may feel slightly plasticky, especially on larger designs. Despite this, it offers excellent longevity and is ideal for vibrant colors and detailed prints.

Screen Printing: Long-Lasting

Screen printing is known for its long-lasting results, with ink bonding directly to fabric, ensuring durability through many washes. The feel is often softer, particularly with water-based inks, offering a comfortable texture on garments.

Materials and Equipment

DTF Supplies: Everything You Need Here! 

DTF printing is versatile and works on a variety of materials such as cotton, polyester, blends, leather, and more. The process requires a DTF printer, which is specifically designed to print onto transparent PET film using water-based inks. 

If you don’t have a DTF printer, no problem! You can use our custom DTF transfers to achieve the same vibrant, high-quality results with ease.

Once the design is printed, hot-melt adhesive powder is applied to the wet ink to ensure it will bond to the fabric. A heat press is then used to transfer the design onto the fabric, activating the adhesive powder and securing the design.

Screen Printing

Screen printing is typically used for flat fabrics like cotton and polyester, but it may require specialized inks for non-traditional materials. The process begins with a screen frame, which holds the stencil for the design. Screen printing ink—usually petroleum-based Plastisol ink, though water-based options exist—is pushed through the mesh onto the fabric. Emulsion and sensitizer are applied to create the stencil, which is exposed to light. After the screen is prepared, it’s cleaned at a washout station, and the ink is cured with a heat source to permanently set it on the fabric.

When should I use Screen Printing vs DTF

If you’re working with small to medium runs, detailed artwork, or vibrant full-color designs, DTF printing is the clear winner. DTF offers superior versatility with minimal setup time—no need for creating multiple screens for each color, making it quick and easy to get started. It’s an ideal choice for custom prints that require intricate details and high-quality results.

While screen printing works best for large quantities of simple designs, DTF shines when it comes to flexibility and efficiency or when you need to print on a variety of materials like cotton, polyester, leather, and more. DTF also excels on dark fabrics, offering the ability to print full-color designs with excellent vibrancy and long-lasting durability. Whether you're running a small shop or tackling custom orders, DTF provides the perfect balance of ease, quality, and efficiency—without the need for complicated setups or large-scale equipment.

Why Choose Atlanta Vinyl for DTF Transfer Supplies

At Atlanta Vinyl, we offer top-quality DTF supplies including transfer films, inks, and adhesive powders to ensure your prints look vibrant and last long. 

We also offer custom DTF gang sheets that allow you to size and arrange your images exactly as needed, filling the sheet with as many designs as possible. 

Whether you’re a small shop or a large printing business, our materials are designed for durability and ease of use. We provide everything you need to get started. With our reliable supplies, you can achieve professional-grade results that stand out—every time.