A side-by-side comparison of the four major t-shirt printing techniques — screen printing, DTG (Direct-to-Garment), all-over sublimation, and discharge printing. Covers cost per piece, minimum quantities, colour limitations, wash durability, and best use cases for each method.
Choosing the right printing method for your t-shirt order can significantly impact cost, quality, and turnaround time. Here is a comprehensive comparison of the four major printing techniques used by Tirupur manufacturers in 2026.
How it works: Ink is pushed through a mesh screen onto the fabric using a squeegee. Each colour requires a separate screen. Best for: Large quantities (500+ pieces), bold designs with 1–6 colours, spot colour logos. Cost: Setup cost $50–150 per colour, then $0.30–0.80 per piece for printing. Wash durability: Excellent — 50+ washes with proper curing. Limitations: Not suitable for photographic or gradient designs, minimum quantity requirements.
How it works: Inkjet technology prints directly onto the fabric using water-based inks. Similar to printing on paper. Best for: Small quantities (1–500 pieces), photographic and full-colour designs, personalised items. Cost: $3–8 per piece depending on print size and complexity. No setup cost. Wash durability: Good — 30–40 washes. Requires proper pre-treatment and curing. Limitations: Best on 100% cotton, not suitable for polyester. Slower than screen printing for large quantities.
How it works: Dye is transferred from paper to fabric using heat and pressure. The dye becomes part of the fabric. Best for: All-over prints on polyester fabrics, sportswear, activewear. Cost: $2–5 per piece for all-over printing. Wash durability: Excellent — the dye is part of the fabric, so it never fades or peels. Limitations: Only works on white or light polyester fabrics. Cannot be used on cotton.
How it works: A chemical agent removes the dye from the fabric, leaving a soft, vintage-effect print. Best for: Dark-coloured t-shirts where a soft-hand, vintage effect is desired. Popular for streetwear and premium fashion brands. Cost: $1–2 per piece additional over standard screen printing. Wash durability: Excellent — the print is part of the fabric. Limitations: Works best on reactive-dyed 100% cotton. Colour options are limited to the base fabric colour.
Screen printing: Best value for large quantities, limited colours. DTG: Best for small quantities and complex designs. Sublimation: Best for all-over prints on polyester. Discharge: Best for vintage effect on dark cotton.
Esplandea Incorporation offers all four printing methods. Our team will recommend the best method for your specific design, quantity, and budget. Contact us for a free quote and sample.