Type Of printing

Screen Printing on Fully Sewn T-Shirts in Mass Manufacturing – Pros and Cons

There are Different printing methods commonly used for t-shirt printing, each with its unique advantages and suitability for different designs and quantities. Here are some of the most popular methods.


  1. Screen Printing: Screen printing is one of the oldest and widely used methods for t-shirt printing. It involves creating a stencil (screen) for each color in the design and then using ink to pass through the screens onto the shirt. This method is cost-effective for large quantities but may be less economical for small batches or designs with multiple colors.
  2. Direct-To-Garment(DTG): DTG printing is a newer technology that allows for high-resolution printing directly onto the fabric using specialized inkjet printers. It is best suited for complex designs or those with a high number of colors, as there are no screen setup costs. DTG is ideal for small to medium quantities.
  3. Heat Transfer Printing: Heat transfer printing involves printing the design onto a special transfer paper and then using heat and pressure to transfer the design onto the t-shirt fabric. This method is suitable for small orders and individual customization, but it may not be as durable as some other methods.
  4. Vinyl Cutting or Heat Press Vinyl: This method involves cutting the design out of colored vinyl sheets and then using a heat press to apply the vinyl onto the t-shirt. It's often used for custom names or numbers on sports jerseys or for designs with a limited number of solid colors.
  5. Sublimation Printing: Sublimation involves printing the design onto special transfer paper using sublimation ink and then using heat to transfer the ink onto polyester or polymer-coated t-shirts. It works best on light-colored garments and is suitable for full-color designs.


Let’s discuss which printing technique you should use if you are in a garment business or thinking to start your own brand. It all depends upon the your need and how you can invest in the beginning. Here we will see some advantages and disadvantages of these methods: 

 8,700+ Screen Printing Stock Photos, Pictures & Royalty-Free ...

Screen Printing


Cost Effective: If you’re looking to produce large quantities of a same design then you can choose it. As once the screen is ready it significantly decreases the cost for next t-shirt, you will print.

Durable Print: Screen printed designs are long lasting as compared to other printing methods, Because the ink directly apply to the fabric and it becomes part of it. It doesn’t faded after few washes.

Can be use Different Materials: You can use screen printing method for different types of fabrics available in the market. So, it is very versatile and the specials links are also available for dark colour fabric.

Suitable for big designs: You can large print while using the screen printing method because it covers the large portion of the t-shirt. As per trend now customer loving the big print designs. So, you can use it for you print.




High setup cost: Making screens for each design of the print can be costly, because setting up a screen is process and it is costly if you want to print less number of quantity. Hence, It is less economical if you want print low quantity and mulitcolour design.

Time consuming for multicolour Designs: For printing multiple colour design you have to make separate screens and then printing each colour will take lot of time. Which led you to longer production time.

Ink Options for Dark Garment: As we know screen printing can be done on dark colour fabrics but it require an under base layer to make colours stand out. This can result in a slightly thicker feel and less breathability on dark shirts.


DTG Printing


Perfect for Complex Designs: DTG printing can accurately print complex designs, Gradient and even photographs. It also offers high quality print with high-resolution.

No Setup cost for colours: Unlike Screen Printing, DTG doesn’t required different screens for different colours which led to low cost setup, which is very useful for small quantity production or for customization.

Time Saving: It is a digital process and it doesn’t required separate screens for each colour. As it can be printed directly by digital file. So, it saves lots time which we invest while making screens.

Breathable Print: DTG printing uses water based inks, resulting soft and breathable print compare to other methods like heat transferring method.



Limited Fabric Compatibility: DTG can’t be used on each type of fabrics. It is best suited for 100% cotton and certain cotton Blends. It may not adhere well to certain synthetic fabrics or materials with special coatings, limiting its versatility.

Higher Cost per Print on Large Order: As we know DTG is cost effective for small orders but it become cot per unit become high for large order.

Prone to Pre-Treatment Stains: To ensure good ink adhesion on the fabric, DTG printing may require pre-treatment of the t-shirt with a special solution. If not done correctly, pre-treatment stains or discolorations can occur on the garment.


Which method you should use??

As per our experience we always recommend to use Screen Printing as it provides the quality and durable print which adds brand value  And in the long run it is also very economical when you print high number of T-shirt. On the other hand, DTG is also effective if you are starting your brand and wanted to do less number of prints. 

While selecting the printing technique you have to consider different aspects i.e. Print Density, Quantity to print, Target Audience etc. After considering all of the above things you should select ideal printing method. In this competitive market you have to give a high quality product to the customer at minimal rate, to achieve this screen printing is always consider first by the industry giants.


Which method is khaaki using??

At khaaki we have different printing techniques available for those brands who wants to choose khaaki as their manufacturer partner. We have expert printing masters who are working in this industry for years. So, you don't need to go to different manufacturers for different prints.