DTF vs. Screen Printing for Small Batch Orders

For decades, Screen Printing was the undisputed champion of custom apparel. It’s classic, durable, and delivers bold colors. But here's the reality for today's entrepreneurs and custom apparel side hustlers: the old champion isn't built for the new game.

If you’re running a small brand, testing new designs, or fulfilling on-demand orders, the hidden costs and complexity of screen printing will kill your profit margins.

Direct-to-Film (DTF) transfers are the game-changer you need. By eliminating the screen printing setup process, DTF becomes the clear, most profitable choice for small batches, one-offs, and custom jobs.

Stop paying setup fees and hitting minimums. Here is the breakdown of why DTF is the smarter, more flexible solution for your business.

The Cost Killer: Setup Fees & Minimums

Screen printing's efficiency only kicks in when you print hundreds of the same design. For anything less, you end up paying an exorbitant premium for prep work.

Setup Cost: Screen printing requires a new, physical screen for every single color in the design. Setup fees often run $25–$50 per screen. DTF Transfers have ZERO setup cost because your design is printed digitally. You pay only for the printed film.

Minimum Order: Screen printing typically requires 12–25 items per design to offset the initial screen cost. DTF Transfers have NO minimums. You can order a sheet to print one shirt or a thousand.

Price per Color: Screen printing cost increases with every color. With DTF, a full-color, photorealistic design costs the same as a single-color logo on the same size sheet.

The DTF Advantage: You eliminate inventory risk and gain the flexibility to test new designs without financial commitment.

Design Flexibility: Go Full Color, Effortlessly

Screen printing is built for simple, block-style artwork. DTF embraces the complexity of modern design.

Intricate Detail & Fine Lines: Screen printing struggles to hold extremely fine lines and small text. DTF transfers use high-resolution digital printing to capture every crisp line and tiny detail perfectly.

Photorealism & Gradients: Want to print a photograph, a detailed illustration, or a design with soft color fades (gradients)? Screen printing requires a complex and expensive process called "simulated process." DTF handles photorealism and smooth color transitions instantly in a single, high-quality pass.

The Soft Feel: Traditional screen printing ink can feel thick and heavy—especially the white base layer on dark garments. DTF transfers are remarkably lightweight and flexible, creating a soft-hand finish that stretches with the fabric, not against it.

Versatility: Print on Everything (Even Difficult Fabrics)

If you only print on 100% white cotton, screen printing works fine. But if your brand uses popular, modern fabrics, DTF offers unmatched versatility.

Fabric Type: Screen printing works best on 100% Cotton but often requires special, expensive inks for synthetic blends. DTF works on almost everything: Cotton, polyester, blends, canvas, nylon, and leather. You use one transfer type across your entire product line.

Dark Colors: Screen printing requires a thick, heavy white underbase to make colors opaque, resulting in a stiff feel. DTF is excellent on dark colors. Our white underbase is automatically applied, providing vibrant, opaque colors on black or dark garments without the heavy feel.

Production Speed: Screen printing requires days of prep work (separating colors, burning and registering screens). DTF is ready to press immediately and applies in under 20 seconds, ensuring the fastest possible turnaround for custom orders.

Conclusion: Which is Right for Your Profit Model?

If you plan to print 500 identical logo shirts for a major event, traditional screen printing may still be your most cost-effective path.

However, for the majority of small business owners and side hustlers in the custom apparel market, the DTF model offers the decisive advantage:

You focus on creating and selling. We handle the complex, messy, and costly printing setup.

You maximize profit by fitting multiple jobs and sizes onto a single, cost-effective gang sheet.

You can react fast to trends and customer requests without being bound by minimum order quantities.

Ready to trade the high setup costs for high-quality, flexible, and profitable transfers?