There are many different decoration methods for garments; with pros and cons for each option.
Silk Screen Printing
Silk screen printing pushes ink through a mesh stencil onto the garment; each color requiring a separate screen. Setup costs are a little higher for multi-color designs, but the per-unit cost drops with volume.
| Minimum Run Size |
24+ (typically) |
| Colors |
1-6+ (cost increases per color) |
| Durability |
Excellent - withstands 50+ washes |
| Best Material |
Cotton, cotton-poly blends |
| Required File Format |
Vector / EPS |
| Pros |
- Lowest per-unit cost at volume
- Extremely durable prints
- Vibrant, opaque colors on dark fabrics
|
| Limitations |
- Setup fees per screen (color)
- Not cost-effective for small runs
- Limited to spot colors (no photographic/gradient prints)
|
Embroidery
Embroidery stitches thread directly into the fabric to create a design. It produces a raised, textured finish that conveys quality and durability. Embroidery does not fade, crack, or peel - the stitching will typically outlast the garment.
| Minimum Run Size |
1 unit (but setup/digitization fees benefit from bulk orders) |
| Colors |
Unlimited thread colors |
| Durability |
Excellent - typically outlasts garment |
| Best Material |
Polos, fleece, bags, towels, blankets, jackets |
| Required File Format |
Vector / EPS for high quality recreation |
| Pros |
- Premium professional finish
- Extremely durable
- Works on thick and textured fabrics
|
| Limitations |
- Not suitable for photographic or highly detailed designs
- Cost increases with design complexity / stitch count
- Small text can be difficult to read
|
Direct-to-Garment (DTG) Printing
Direct to garment printers spray water based ink directly onto the fabric, similar to an inkjet printer. This allows unlimited colors and photographic-quality prints without screen setup costs.
| Minimum Run Size |
1 unit |
| Colors |
Unlimited (CMYK process) |
| Durability |
Good; 30-50 washes with proper care |
| Best Material |
100% cotton (best), poly blends (possible) |
| Required File Format |
PNG with transparent backgrounds (300 DPI)
Vector / EPS for best print quality
|
| Pros |
- No setup fees
- Full-color photographic prints
- Cost-effective at single unit quantities
|
| Limitations |
- Works best on 100% cotton
- Less durable than screen printing with high wash counts
- Dark garments require white underbase (adds cost)
|
Direct-to-Film (DTF) Printing
Direct to film prints a design onto a special transfer film using inkjet printing, then heat presses it onto the product. DTF works on fabrics that direct-to-garment can't handle well like polyester, nylon, and blends.
| Minimum Run Size |
1 unit |
| Colors |
Unlimited (CMYK process) |
| Durability |
Very good - comparable to screen printing |
| Best Material |
Cotton, polyester, nylon, blends, leather |
| Required File Format |
PNG with transparent backgrounds (300 DPI)
Vector / EPS for best print quality
|
| Pros |
- Works on almost any fabric
- Vibrant colors on dark garments without quality loss
|
| Limitations |
- Slightly raised texture (the transfer film sits on the fabric)
|
Sublimation
Sublimation uses heat to convert dyes into gas, which permanently bonds with polyester fibers. The result is a vivid, all-over print that won't crack, fade, or peel.
| Minimum Run Size |
1 unit |
| Colors |
Unlimited (CMYK process) |
| Durability |
Excellent - the dye is part of the fabric |
| Best Material |
White or light-colored polyester only |
| Required File Format |
PNG with transparent backgrounds (300 DPI)
Vector / EPS for best print quality
|
| Pros |
- All-over edge-to-edge printing
- No texture or hand feel - the print is part of the fabric
- Extremely durable, won't crack, peel, or fade
|
| Limitations |
- Only works on polyester fabrics
- Only works on white or very light-colored fabrics
- Cannot produce opaque white
|
Heat Transfer / Vinyl
Heat transfer vinyl is cut into a shape using a plotter or laser cutter, then heat-pressed onto the garment. It's ideal of individualized items like names, numbered shirts, etc.
| Minimum Run Size |
1 unit |
| Colors |
Per-color layer (1-3 typical) |
| Durability |
Good - 25-40 washes |
| Best Material |
Cotton, polyester, nylon |
| Required File Format |
PNG with transparent backgrounds (300 DPI)
Vector / EPS for best print quality
|
| Pros |
- Ideal for personalization (names / numbers)
- Available in metallic, reflective, and specialty finishes
|
| Limitations |
- Limited to 1-3 colors per design
- Not suitable for photographic or gradient designs
- Less durable than screen printing or embroidery
|