Ultimate Guide To Choose The Best Printing Method For Your POD T-Shirt BrandAre you an aspiring T-shirt designer with a ton of ideas and a dream? Are you looking for a suitable way to print your POD T-shirts? This guide will show you every printing method possible, through the words of POD expert Marc Katz - Senior Product Manager of the famous brand Lion King Shirt. By understanding the strengths and weaknesses of each option, you can pursue the ideal balance of quality and costs.Screen Printing For High Volume Orders1. The Tried And True Printing MethodSince the 1960s, screen printing has been the go-to printing method for T-shirts. The process uses a screen of fine mesh fabric to apply each color to the shirts. Durable inks are pressed through the mesh onto the fabric, using a rubber squeegee.
This analog method has dominated the T-shirt industry for decades, thanks to its ability to print high volumes quickly, efficiently, and cost-effectively. It remains the standard printing approach for large orders of over 50 shirts. You will need a high upfront investment for the equipment, but it pays off over massive production runs.
The old-school screen printing method is a safe choice2. Pros: Vibrant And Durable ResultsBy layering multiple color screens, screen-printed shirts can create vibrant colors and artistic blends. In the experienced screen printing shops, they develop proprietary inks and techniques to create stunning graphic effects that digital effects can never do. Compared to other printing methods, screen-printed designs hold up exceptionally well through repeated washing and extended wear.
3. Cons: High Setup CostsAs mentioned earlier, you’d have to invest quite a lot for the equipment, so this method won’t work for small, customized orders. The process requires creating a unique screen for every color in the T-shirt design. For complex graphics, this setup time multiplies. If you’re looking to make a one-off prototype order, try looking for other digital printing methods with lower setup costs.
Heat Transfer Printing For Short Jobs1. Minimal Setup RequirementsMarc Katz Shapes the Future of Product and Content Development, and according to him, heat transfer printing is much simpler than screen-printing. The changes will be created through digital printing or vinyl cutting, and then a heat press will print them onto the T-shirt.
This minimal setup makes heat transfer ideal for small orders and rapid prototyping. You don’t need to buy any screens or plates beforehand. The short turnaround lets you test your new T-shirt designs, then edit them before committing to a full production run.
2. Pros: Photorealistic GraphicsThanks to heat transfer’s digital nature, it can easily reproduce realistic images. You can create complex photographic T-shirts without investing in screen-printing setup.
There are many types of transfer papers that suit different images. Sublimation inks transfer photos, graphics, and logos when applied to polyester. Inkjet transfer paper works well for printing on cotton and darker fabrics.
3. Cons: Varying DurabilityThe durability of the image depends heavily on the materials used and the application technique. Sublimation inks will dye the fibers directly, so designs hold up exceptionally well over time. Meanwhile, inkjet transfers sit atop fabrics, so they may degrade faster if washed a lot. Overall, the durability of the heat transfer method still cannot beat screen printing.
Direct-To-Garment For On-Demand Printing1. Digital And On-Demand CapabilityDirect-to-garment (DTG) printing uses specialized inkjet printers to print directly onto the fabric. No transfers are required. The T-shirts are loaded directly into the DTG device, which prints the design right onto the surface of the fabric.
This makes DTG ideal for on-demand production. Orders can be taken and fulfilled as they come in without batching for efficiency or wasting materials. The DTG process easily accommodates single prints and limitless design variations.
Direct-to-garment is a new-school approach for POD T-shirts2. Pros: Soft Hand FeelBecause the ink is jetted directly onto the fabric using a mechanical print head, DTG T-shirts retain a soft and smooth surface, much similar to when it was a blank tee. This is a clear improvement from heat transfer papers - they create a plasticky overlay over designs.
DTG's soft hand matches screen printing, but doesn’t have any high setup costs. It brings high-resolution photographic printing quality to small batches with quick turnaround times.
3. Cons: Marginally Higher Costs Per UnitIf you produce in bulk, DTG printing will cost you a bit more to produce each
Lion King Shirt, compared to screen-printing or heat transfer orders. However, for smaller quantities, DTG excels and the price difference is reduced drastically. For small orders under 50 units, DTG provides digital convenience and soft-hand feels, which are ideal for quality-focused startups.
Last CommentsAll in all, the expert Marc Katz has just shown you the most popular printing methods for creating POD T-shirts, as well as their strengths and drawbacks. Your mission is to consider the budget, the growth stage, and the needs of your brand, so as to choose the optimal method. Make the right choices and your T-shirts will reach new heights!
3 Replies
621 Views