Silkscreen printing, also known as screen printing, is a popular traditional technique for printing designs on t-shirts. It's a versatile and durable method, ideal for creating bold, vibrant images. Here's how it works:
Creating the Screen: The design to be printed is then transferred to the screen by blocking certain areas with a special emulsion that hardens when exposed to light, while leaving other areas open (the design areas).
Preparation of Ink: Once the design is on the screen, ink (typically plastisol or water-based) is prepared. Plastisol ink is the most common for t-shirts because it’s durable and has a rich, glossy finish.
Printing: Ink is placed on the top of the screen, and a squeegee is used to push the ink through the open areas of the screen onto the t-shirt fabric. Each color in the design requires a separate screen. For multi-color designs, the t-shirt will pass through several screens, one for each color layer.
Curing: After the ink is applied, the printed design is heated to set the ink into the fabric, ensuring that it’s durable and won't wash out easily.
Advantages:
Durability: Silkscreen prints are long-lasting and can withstand numerous washes without fading.
Vibrancy: The ink used in silkscreen printing provides vibrant, bold colors, especially for designs with solid areas.
Cost-effective for Large Runs: It’s ideal for bulk printing, as the setup process can be time-consuming, but once established, it becomes cost-effective for large quantities.
Versatile: Works on a variety of materials, including cotton, polyester, and blends.
Disadvantages:
Limited Detail: Fine details or very intricate designs can be harder to achieve with silkscreen printing. It's better suited for bold, simple designs or designs with a few colors.
Setup Time: The initial setup for screen printing can be time-consuming, especially for designs with multiple colors. This is why it’s more cost-effective for large orders than for small ones.
Environmental Impact: The process can involve chemicals (like photo emulsions) and ink that is not environmentally friendly.
In short, silkscreen printing is a durable, cost-effective, and versatile method that's perfect for creating high-quality t-shirt prints, especially when you’re looking to produce large volumes.
DTG printing is another popular method for printing designs on t-shirts, and it works quite differently from silkscreen printing. DTG allows for high-quality prints with a lot of detail and is ideal for small batches, intricate designs, and multi-colored graphics.
Process:
Preparation of the garment: The fabric is usually pre-treated to ensure the ink adheres well and produces vibrant colors. This pre-treatment is especially important for colored fabrics.
Printing: The DTG printer is similar to an inkjet printer and it uses specialized water-based inks that are sprayed directly onto the shirt using tiny nozzles. The printer prints layer by layer, and it can handle full-color designs, including gradients and intricate details.
Curing: After the design is printed, the t-shirt is heat-treated to cure the ink. This step is important for ensuring the ink bonds with the fabric and becomes durable, preventing it from washing out.
Advantages:
High Detail: DTG can produce designs with high levels of detail and complex color gradients. It’s perfect for designs that have a lot of fine detail or photorealistic images.
No Color Limitations: Unlike silkscreen printing, DTG doesn’t require separate screens for each color. You can print full-color images with ease, including photographic images and intricate designs.
Quick Setup for Small Batches: There’s no setup like in silkscreen printing, making it a more time-efficient and cost-effective option for small runs or one-off designs.
Eco-friendly: Since DTG uses water-based inks and doesn’t require screens, it has a smaller environmental footprint than silkscreen printing.
Disadvantages:
Durability: While DTG prints are high quality, they tend to be less durable than silkscreen prints, especially after multiple washes. The ink sits on top of the fabric rather than bonding with it, so it can fade or crack more easily over time.
Cost for Large Orders: For bulk printing, DTG can become more expensive compared to silkscreen printing due to the cost of ink and slower print times for large batches. It’s better suited for smaller orders.
Limited on Fabric Types: DTG works best on 100% cotton fabrics, and is less effective on blend fabrics. The print on blend fabrics will usually result in some dye migration changing the print colour slightly.
When to Use DTG:
Small batches or custom prints: DTG is great for printing a small number of shirts with complex designs or custom prints, making it ideal for on-demand printing.
More complex designs: DTG shines with multi-colored designs, photos, or artwork with fine details. Smoke and flames, grunge designs, and vintage/retro type of designs are perfect for DTG.
Soft feel: The ink is absorbed into the fabric, giving the printed design a softer, more natural feel compared to the thick, slightly raised ink used in silkscreen printing.
Special Note for DTG:
There is a distinct print difference in terms of colour and feel when using DTG printing on white colour t-shirts and colour t-shirts. The ink is fully absorbed into the white t-shirt fibers, giving it a non-existent print feel. As a result, the print is not as vibrant when compared to other methods. Therefore, when the same design is printed on both white and colour t-shirts, the print colour and feel will be different.
In Summary:
Direct to Garment printing is a great choice for intricate, colorful designs and small print runs. It’s quick and easy to set up for custom prints, but it’s not as durable as silkscreen printing, especially for large quantities. It’s best for situations where high detail, vibrant colors, or one-off designs are needed, such as custom orders or limited edition prints.
DTF printing is a relatively newer method of printing designs onto t-shirts, and it’s gaining popularity due to its versatility, ease of use, and high-quality results. DTF printing works similarly to Direct to Garment (DTG) printing but with a different process and some distinct advantages.
Process:
Printing the Design: In DTF printing, the design is printed directly onto a special film (a type of transfer film) using a specialized printer. The printer uses CMYK and white ink to print the design. The white ink is important because it creates a vibrant base for the colors, especially when printing on dark fabrics.
Powder Adhesive: Once the design is printed onto the film, a special adhesive powder is applied to the print while the ink is still wet. The powder sticks to the ink, which is then cured using a dryer. This step is essential because the powder helps the design stick to the fabric once it's transferred.
Transfer to the Shirt: The printed and powder-coated film is then placed on the t-shirt. Using a heat press, the design is transferred from the film onto the fabric. The heat press activates the adhesive, ensuring the ink bonds well with the fabric.
Curing: After the transfer process, the shirt is typically heat-pressed once more to ensure the design is fully set and durable.
Advantages:
Great for Various Fabrics: DTF printing works well on a wide range of materials, including cotton, polyester, blends, and even non-fabric items like bags, hats, and more.
Vibrant Colors and Detail: Like DTG, DTF prints are capable of handling full-color designs with intricate details. The use of white ink allows for vibrant, solid colors, especially when compared to DTG print on a white t-shirt.
Cost-effective for Small and Medium Runs: DTF printing is more affordable than silkscreen printing for medium-sized orders especially when with multi-colour designs.
Disadvantages:
Complexity with Large Runs: For large quantities, DTF printing can be less efficient than silkscreen printing, as each design needs to be transferred individually.
Softness: While DTF prints are durable, they may not feel as soft as DTG prints. The transfer layer can sometimes feel slightly more rigid compared to the softer, ink-absorbed feel of DTG prints.
Minimum thickness: When compared to DTG, there is a minimum recommended thickness of 0.85mm to avoid any missing prints. Therefore, DTF is not suitable for designs with lots of thin strokes, brushes, or vintage looks.
When to Use DTF:
Vibrant prints on white t-shirts: DTF printing is a great option for vibrant prints on white colour t-shirts, especially when compared to DTG.
Versatility with Fabrics: DTF printing is an excellent choice for printing on various fabric types, such as polyester and blend materials.
Full Colour Designs: If you’re printing custom designs or a small number of shirts, DTF is a great option. It allows for full-color designs and detailed prints without the complex setup of silkscreen.
In Summary:
Direct to Film printing is a versatile and efficient method that is similar to DTG. It works on a variety of fabrics, offers vibrant colors, and delivers durable results, making it an excellent choice for custom orders, small-to-medium runs, and vibrant designs.
