When you’re ordering custom apparel, it helps to know how the printing works. This guide explains the difference between screen printing, embroidery, and DTF (Direct-to-Film), so you can pick the best method for your design.
Screen Printing
Screen printing is great for bold, solid designs and large orders. It uses a mesh stencil for each color, pushing ink onto your shirts. In bulk runs, this method is very cost-effective. It handles detailed graphics (even fine text) and gradients well, creating smooth color fades. It also works on delicate fabrics since no needles are involved.
The trade-off is that each ink color needs its own screen, so multi-color jobs cost more. Dark fabrics also require a white underbase layer to help colors pop. In short, pick screen printing for large quantities and detailed, vibrant prints.
Embroidery
Embroidery stitches your design with colored threads, giving a professional, long-lasting look. It’s ideal for logos on polo shirts, jackets, hats, and tough workwear. Polyester threads used in embroidery are highly durable – they hold up to bleach, heavy wash cycles, and rough use.
Embroidery also adds a raised, textured effect that feels premium. However, it’s not ideal for very small text or intricate details. Keep letters at least ¼″ tall so stitches stay crisp. Also, avoid designs with subtle fades, as thread colors are solid and can’t blend. Choose embroidery for a durable, upscale look on thicker fabrics.
DTF (Direct-to-Film)
DTF printing is a newer digital method where your artwork is printed onto a special film, coated with adhesive powder, and then heat-pressed onto the garment. The result is a vibrant, full-color image that applies well even on dark or stretchy materials.
DTF excels with complex, multi-color designs and can reproduce fine details and gradients in a single pass. There's no need for a white underbase on dark shirts since the transfer has its own backing. It’s fast, setup costs are low, and it’s great for small runs or one-off designs. The only drawback is that DTF prints sit on top of the fabric, so they may feel a bit less “woven-in” than screen prints.
Which Method Should You Use?
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Screen printing: Best for big orders with 1–4 colors and bold graphics. It’s durable and cost-effective per unit.
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Embroidery: Best for professional workwear (polo shirts, jackets, hats). Creates a high-quality logo that lasts through heavy laundry. Avoid tiny text or fades.
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DTF printing: Best for small runs or detailed designs. Handles complex, multi-color artwork and works well on dark or stretchy fabrics.
Still unsure? Think about your priorities:
Durability & premium feel → go with embroidery
Bulk pricing & simple graphics → choose screen printing
Detailed full-color designs → pick DTF
Whichever you choose, our Dalton team can help with samples and quotes. Ready to get started? Contact our local print shop today for a free quote on your custom apparel project. We’ll help you pick the right method and deliver high-quality results.
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