DTG vs. Screen Printing: Best Choice for Small vs. Large Orders

Here's a question we answer just about every day: "Should I do DTG or screen printing?" And the honest answer is that it almost always comes down to two things — how many shirts you need and how complicated your design is. Get those two straight and the right method practically picks itself.

Let's make it easy.

What's the difference between DTG and screen printing?

Screen printing pushes ink through a stencil (a "screen") — one screen per color. There's setup work to burn those screens, but once they're ready, printing 200 shirts is fast and cheap per piece. It's the workhorse of big orders.

DTG (direct-to-garment) works like an inkjet printer for shirts, spraying the design straight into the fabric. No screens, no setup, no minimum — just hit print. That makes it perfect for one shirt, a dozen shirts, or a design with a hundred colors.

Same goal, opposite strengths: screen printing loves volume, DTG loves flexibility.

When is DTG the better choice?

Reach for DTG when:

• You need a small quantity — anything from 1 to about 24 shirts, where screen-printing setup isn't worth it.
• Your design is full-color, photo-realistic, or full of gradients — the kind of art that would need a dozen screens.
• You're printing on soft 100% cotton and want the print to feel like it's barely there.
• Every shirt might be a little different — DTG doesn't care if shirt #3 has a different graphic than shirt #4.

Think boutique tees, one-off gifts, art prints, and short runs with complex designs.

When does screen printing win?

Screen printing is the move when:

• You're ordering 25 or more of the same design — that's where the per-shirt price really drops.
• Your design is bold and simple — 1 to 3 solid colors, clean shapes.
• You want the lowest possible price per shirt on a big run.
• You need it on any fabric, including performance blends where DTG struggles.

Think team orders, company shirts, event tees, and any job where you're printing the same thing a whole lot of times.

Where's the crossover point?

This is the real question. The more ink colors your design has, the more screen setups screen printing needs — which pushes the crossover point higher. Here's the rough guide:

Order Size	Best Method	Why
1–24 shirts	DTG	No minimum, no setup fees
25–72 shirts	Depends on colors	Simple art favors screen; complex favors DTG
72+ shirts	Screen printing	Lowest per-shirt price at volume
Full-color art (any qty)	DTG	Handles photos and gradients screens can't

The gray zone is that 25-to-72 band. A simple 1-color logo on 50 shirts? Screen print. A 6-color illustration on 50 shirts? DTG may actually come out ahead once you count all those screen setups. When in doubt, we'll price it both ways and tell you which wins.

Does one last longer or feel better?

Both hold up for years with proper care. Screen printing lays ink on top of the fabric — durable, vibrant, and slightly more substantial to the touch, especially on big solid prints. DTG soaks into the fabric for a softer, lighter feel that many people prefer on a premium cotton tee. Wash either one inside-out in cold water and skip the dryer's highest heat, and they'll go the distance.

Short version: screen printing feels a touch bolder, DTG feels softer. Neither is "better" — it's preference.

How do you decide?

Start by browsing our custom apparel collection and picking your garment. On any apparel product page, flip on the Add Decoration tool, enter your quantity and design details, and you'll see pricing by method — which makes the DTG-vs-screen-print math obvious at a glance. Not sure which way your order tips? Send us your design and headcount and we'll price it both ways.

Frequently asked questions

Is DTG or screen printing better for small orders?
DTG is better for small orders. It has no minimum and no screen setup fees, so printing 1 to 24 shirts is more economical than screen printing, which is built for larger runs.

Is DTG or screen printing cheaper for large orders?
Screen printing is cheaper for large orders of the same design. Once you clear the 25-piece minimum, the per-shirt price drops steadily as quantity rises, which DTG pricing does not do as sharply.

At what quantity does screen printing become cheaper than DTG?
Usually somewhere between 25 and 72 shirts, depending on ink colors. Simple 1 to 3 color designs cross over sooner; complex full-color designs favor DTG even at higher counts because each color adds a screen.

Does DTG or screen printing last longer?
Both last for years with proper care. Screen printing is slightly more substantial on solid prints, while DTG is softer. Washing inside-out in cold water and avoiding high dryer heat keeps either one looking sharp.

Can DTG print any design?
DTG handles full-color, photo-realistic, and gradient designs that would need many screens in screen printing. It performs best on 100% cotton and lighter garments.

What's the minimum order for screen printing vs DTG?
Screen printing starts at a 25-piece minimum. DTG has no minimum, so you can order a single shirt. That difference is the main reason DTG wins on small orders.