The world of custom apparel printing is a competitive one, with various techniques vying for dominance. Two of the most popular methods, Direct-to-Garment (DTG) and screen printing, have been pitted against each other in a battle of cost-effectiveness. The question on everyone’s mind is: which method is cheaper? In this article, we’ll delve into the costs associated with DTG and screen printing, exploring the factors that affect pricing and helping you determine which technique is best for your business or personal needs.
Understanding the Basics of DTG and Screen Printing
Before we dive into the costs, it’s essential to understand the basics of both DTG and screen printing.
Direct-to-Garment (DTG) Printing
DTG printing is a relatively new technology that allows for the direct printing of designs onto garments using specialized inkjet printers. The process involves pre-treating the garment, loading it into the printer, and printing the design directly onto the fabric. DTG is known for its high-quality prints, photo-realistic images, and ease of use.
Screen Printing
Screen printing, also known as silk screening, is a traditional method that involves creating a stencil of the design on a screen, then applying ink to the screen to print the design onto the garment. The process requires a separate screen for each color, making it more labor-intensive and costly for small orders.
Cost Breakdown: DTG vs. Screen Printing
The costs associated with DTG and screen printing vary depending on several factors, including the type of garment, design complexity, order quantity, and printing technique used. Here’s a breakdown of the costs:
Initial Investment
| Printing Method | Initial Investment |
| — | — |
| DTG Printer | $10,000 – $50,000 |
| Screen Printing Equipment | $5,000 – $20,000 |
The initial investment for DTG printing is significantly higher than screen printing. This is because DTG printers are specialized inkjet printers that require a substantial upfront investment. Screen printing equipment, on the other hand, can be more affordable, but the cost of creating screens and ink can add up over time.
Operating Costs
| Printing Method | Operating Costs (per hour) |
| — | — |
| DTG Printer | $5 – $20 |
| Screen Printing | $10 – $50 |
Operating costs for DTG printing are relatively low, as the printer only requires electricity and ink to function. Screen printing operating costs, however, can be higher due to the need for labor to create screens, apply ink, and clean the equipment.
Garment Costs
| Garment Type | DTG | Screen Printing |
| — | — | — |
| T-shirt | $2 – $5 | $2 – $5 |
| Hoodie | $5 – $10 | $5 – $10 |
| Long-sleeved shirt | $3 – $6 | $3 – $6 |
Garment costs are relatively similar for both DTG and screen printing. The cost of the garment depends on the type, quality, and brand. Some printers may charge more for certain types of garments due to the specialized ink or treatments required.
Design Complexity
Design complexity plays a significant role in determining the cost of printing. Simple designs with few colors can be less expensive to print, while complex designs with many colors and layers can be more costly.
| Design Complexity | DTG | Screen Printing |
| — | — | — |
| Simple design | $1 – $3 | $2 – $5 |
| Complex design | $5 – $10 | $10 – $20 |
DTG printing is generally more cost-effective for simple designs, as it requires less labor and materials. Screen printing, on the other hand, can be more expensive for complex designs, as it requires creating multiple screens and applying ink.
Minimum Order Quantity (MOQ)
MOQ is a critical factor in determining the cost-effectiveness of DTG and screen printing. Most screen printers require a minimum order quantity of 12-24 garments, while DTG printers can print as few as 1 garment.
MOQ Cost Comparison
| MOQ | DTG | Screen Printing |
| — | — | — |
| 1-5 garments | $10 – $20 | $20 – $50 |
| 6-12 garments | $10 – $20 | $15 – $30 |
| 24-50 garments | $5 – $10 | $10 – $20 |
As you can see, DTG printing is often more cost-effective for small orders, while screen printing is more suitable for large orders. However, this can vary depending on the printer, design complexity, and garment type.
Other Costs to Consider
When comparing the costs of DTG and screen printing, it’s essential to consider other factors that may affect pricing. These include:
Shipping Costs
Shipping costs can vary depending on the location, package weight, and shipping method. Make sure to factor in shipping costs when calculating the total cost of printing.
Design Costs
If you don’t have a design, you may need to hire a designer or pay for design software. This can add to the overall cost of printing.
Taxes and Fees
Taxes, fees, and licenses can vary depending on your location and type of business. Be sure to factor these costs into your calculations.
Conclusion
While both DTG and screen printing have their advantages and disadvantages, the cost-effectiveness of each method depends on your specific needs and requirements. If you’re looking for a cost-effective solution for small orders or complex designs, DTG printing may be the better option. However, if you’re printing large quantities of simple designs, screen printing may be more suitable.
Ultimately, it’s crucial to research and compares prices from different printers, considering factors such as garment costs, design complexity, MOQ, and shipping costs. By doing so, you can make an informed decision and choose the printing method that best fits your budget and needs.
What is DTG printing?
DTG (Direct-to-Garment) printing is a digital printing process that allows for high-quality, full-color prints directly onto textiles such as t-shirts, hoodies, and hats. This technique uses inkjet technology, allowing for intricate designs and small orders with great precision and detail. DTG printing is commonly used for small to medium-sized orders, as it eliminates the need for screens and large setup costs.
In DTG printing, ink is applied directly to the garment, allowing for a wide range of colors and effects that can be easily replicated. This process is perfect for detail-oriented designs and photograph-based prints, resulting in vibrant, high-quality images on your chosen garments. With DTG, you can enjoy low minimum order quantities and fast turnaround times without the added expense of screen setup fees.
What is screen printing?
Screen printing is a centuries-old printing technique that involves pushing ink through a mesh screen to transfer an image onto a garment. A separate screen is needed for each color in the design, which requires manual setup, film positives, and a lot of labor to produce. This traditional process is often used for large orders, long production runs, and bold designs that cover a large surface area.
As the number of colors in the design increases, so does the time and cost associated with setting up each screen. However, once the screens are prepared and the ink starts flowing, screen printing becomes quite efficient, which is why it’s often used for mass production and commercial printing. Although it requires more initial investment and has higher minimum order quantities than DTG printing, screen printing can result in affordable costs per unit in large orders.
What factors affect the cost of DTG printing?
Several factors contribute to the overall cost of DTG printing, including the number of garments, design complexity, color count, fabric type, and branding or labeling. The more intricate the design, the higher the cost due to increased ink usage, production time, and printer wear. Fabric type also affects cost, as specialty fabrics or larger garments may be more expensive to print than standard cotton t-shirts.
In addition to these factors, ink and supplies may be pricier for DTG printing due to the specific technology and materials required. This includes inkjet ink cartridges, curing machines, and replacement parts. Given the advanced technology and complexity of the process, it’s essential to carefully balance these factors to ensure cost-effectiveness.
What factors affect the cost of screen printing?
Key factors affecting the cost of screen printing include the number of colors in the design, the number of prints (order quantity), screen setup costs, fabric type, and the number of locations on the garment (i.e. front, back, and sleeves). The more colors in the design, the higher the setup cost and the more labor-intensive the process. Order quantity and fabric type also significantly impact the cost, as large orders or specialized materials often lead to higher prices.
Furthermore, setting up each screen for multiple colors or multiple locations on the garment adds labor and preparation costs. This is why screen printing often comes with minimum order quantities – the initial investment and setup costs need to be justified by a substantial order size. Optimal pricing can usually be achieved for large orders or when using simple, one-color designs.
Which method is more cost-effective for small orders?
Given the setup costs and labor required for screen printing, DTG printing is often more cost-effective for small orders or customized prints. With no need to pay for multiple screens, this process can turn out a single order with detailed, high-resolution prints at a more affordable price. Even with specialty fabrics or complex designs, DTG can minimize costs per unit for orders requiring a handful or even just one garment.
Keep in mind that as the order quantity increases, the savings associated with screen printing grow. So while DTG provides an inexpensive alternative for small to medium-sized orders, larger orders (over 200-500 units) can show increasing economies of scale for screen printing, especially with one or two-color designs.
Are there situations where screen printing is cheaper than DTG?
Yes, there are scenarios where screen printing can be the more affordable option. Large orders, simple designs with few colors (one or two), and multiple prints per order make screen printing more cost-effective in the long run. Once the initial screen setup costs are accounted for, subsequent units become relatively inexpensive, as the fixed setup costs can be spread across many garments. This results in savings per unit compared to the cost per unit for DTG.
By minimizing the number of colors and printing large quantities, businesses can benefit from the efficiency and cost-effectiveness of screen printing. For large, high-volume orders, it becomes difficult for DTG to compete with the economies of scale offered by screen printing.
Does the fabric type affect the cost of DTG and screen printing?
Yes, the type of fabric and garment selected for printing affects both DTG and screen printing costs. In the case of DTG printing, certain fabric types or specialty blends may be more challenging or expensive to print on due to the specific characteristics of the material (stretchiness, density, etc.). Screen printing is relatively more flexible in terms of fabric types, with only thicker fabrics, like canvas or heavy cotton, requiring specialized considerations.
Given the differences in the way ink interacts with different fabrics, manufacturers should take fabric type into account when calculating costs and comparing between DTG and screen printing options. Costs and printing times may vary based on fabric selection, so partnering with experienced printing partners can help you make informed decisions about the optimal method for your chosen fabrics.