Direct-to-garment (DTG) printing and screen printing are the two most common methods for producing branded uniforms, and each has distinct advantages depending on your order volume, design complexity, and client expectations. Choosing the wrong process can eat into your margins, slow down turnaround times, or deliver subpar results that damage your reputation. Understanding when to use each method is essential for growing a profitable custom uniform business.
How Direct-to-Garment Printing Works
DTG printing applies ink directly to the fabric using specialized inkjet technology, similar to printing on paper. The garment sits flat on a platen, the printer head moves across it, and high-quality color images are deposited into the fibers. Setup is fast—typically 5–10 minutes—making it ideal for small runs or one-off orders.
Cost per unit: $8–18 per shirt, depending on ink coverage and garment quality. There's no significant setup fee, so you can profitably print 1–50 shirts without pressure to minimize costs per piece.
Quality: DTG excels at photorealistic images, gradients, and multi-color designs with fine detail. Colors remain vibrant and the finish feels soft to the touch, which appeals to premium uniform clients.
Turnaround: Most orders print within 24–48 hours. This speed is a major selling point when clients need uniforms quickly or when you're responding to leads in real time.
How Screen Printing Works
Screen printing pushes ink through a mesh screen onto fabric, one color at a time. Each color requires a separate screen and a pass through the press, making the process slower for complex designs but faster (per unit) for large volumes.
Cost per unit: $2–6 per shirt on orders of 100+ pieces. Setup costs $50–150 per screen per color, so you need volume to justify the investment. A 500-unit order with a 3-color design pays off; a 20-unit order does not.
Quality: Screen printing produces vivid, durable prints that withstand heavy washing and industrial work environments. The ink sits on top of the fabric rather than sinking in, which some workwear clients prefer for longevity and opacity.
Turnaround: Setup and curing take 1–2 weeks, depending on screen production and production queue. This longer lead time requires advance planning and clear communication with clients.
When to Use Each Method
Choose DTG when:
- Clients order 1–75 units per design
- Designs feature photographs, complex gradients, or more than 4 colors
- You're fulfilling rush orders (within 48 hours)
- Clients want samples or test prints before committing to large quantities
- You're selling through a listing on a marketplace like Mercoly, where small, customized orders are common and visibility matters for lead generation
Choose screen printing when:
- Clients order 100+ identical units
- Designs are simple (1–3 solid colors)
- Clients need the lowest per-unit cost
- Durability under heavy use (industrial laundries, frequent washing) is critical
- You're building a long-term relationship with a single client (e.g., a restaurant chain ordering branded polos quarterly)
Practical Considerations for Your Business
Equipment investment: DTG printers cost $15,000–40,000 upfront; screen printing setups are $5,000–15,000. DTG requires more maintenance (heads clog if unused for days), while screen printing requires careful screen reclamation and storage.
Garment sourcing: Both methods work on cotton, cotton-blends, and polyester. Verify that your DTG printer is rated for the fabrics you want to offer; some struggle with dark synthetics. Screen printing adapts to almost any woven or knit fabric.
Staffing: DTG runs demand minimal training—load the garment, hit print. Screen printing requires skilled press operators to register colors correctly and maintain consistent ink viscosity.
Scaling: Start with DTG to onboard clients quickly and test demand. Add screen printing equipment once you have 5–10 repeat clients ordering 200+ units monthly.
Frequently Asked Questions
Q: Can I use DTG ink on heavy workwear fabric like 100% cotton canvas? A: Yes, DTG works on canvas, but results depend on your printer's penetration settings and the ink formula. Test with your supplier first, as thicker fabrics may require extended curing time.
Q: Which method fades faster in sunlight? A: Screen printing inks (especially discharge inks) generally outlast DTG on garments exposed to constant UV, such as outdoor safety uniforms. DTG has improved significantly but isn't ideal for full-sun environments.
Q: How do I decide pricing—do I charge the same for both methods? A: No. DTG costs more per unit but has no setup fee; screen printing has high setup but low per-unit cost. Quote DTG orders at 3–4x the per-shirt cost and screen-printed orders at the per-unit rate plus amortized setup across the run.
Ready to grow your uniform business? List your services on Mercoly today to reach customers actively searching for custom workwear solutions.