Screen Printing vs DTG vs Sublimation
Choosing the wrong printing method is one of the most common and costly mistakes clothing brands make in production. Each method has different cost structures, quality characteristics, fabric requirements and minimum quantities. This guide explains the three primary garment printing methods — screen printing, DTG and sublimation — and when to use each one.
The three printing methods
Screen Printing — Best for Bulk, Bold Designs
Screen printing is the most commonly used garment decoration method and the most cost-effective for bulk orders with simple, bold designs. A separate screen is made for each colour in the design — creating a setup cost that is fixed regardless of quantity. The more units you print, the lower the per-unit cost.
DTG Printing — Best for Complex Artwork and Smaller Runs
Direct-to-garment printing uses inkjet technology to print directly onto the fabric surface — like a standard printer but built for garments. No screens, no colour limits, no setup cost per colour. This makes DTG ideal for complex designs, photo-quality artwork and smaller runs where screen setup cost would be disproportionate.
Sublimation Printing — Best for All-Over Print on Polyester
Sublimation printing uses heat to bond dye directly into polyester fabric fibres — creating a permanent, full-coverage print with no texture and no risk of cracking or peeling. The only method capable of true all-over print coverage without seam interruption.
Screen Printing vs DTG vs Sublimation, Side by Side
| Attribute | Screen Printing | DTG | Sublimation |
|---|---|---|---|
| Best for | 100+ units with 1-8 solid colours | Complex multi-colour artwork, photo prints, smaller runs | All-over print (AOP) on polyester activewear, sports kits |
| Cost structure | Setup cost plus per-unit print cost — costs decrease with volume | Per-unit cost only — no setup cost | Per-unit cost — scales well at higher quantities |
| Colour limit | Up to 8 colour separations per design | Unlimited — photographic quality | Unlimited |
| Fabric | Works on all fabric types | Best on 100% cotton and high-cotton blends | Must be 100% polyester or high polyester content |
| Durability | Excellent — plastisol ink is highly durable | Good — proper wash care extends print life | Excellent — colour is part of the fabric |
| Detail level | Good for bold designs — not suitable for fine gradients | Excellent — photographic quality possible | Excellent — photographic quality |
Which Method Fits Your Order?
Choose Screen Printing When
You are ordering 100+ units with 1-8 solid colours, want the most durable print result, are printing on cotton or mixed fabrics and want the lowest per-unit cost at scale.
Choose DTG When
Your design has more than 8 colours, includes gradients or photographic elements, you are ordering smaller quantities or need individual personalisation within a single order.
Choose Sublimation When
You want all-over print coverage, your garments are 100% polyester, you are producing activewear, sports kits or swimwear with full-coverage graphic designs.
Printing methods, answered.
Can I use more than one printing method on the same garment?
Yes. Combining methods — for example, a sublimation base with screen printed chest graphic — is available at ZN Apparel Manufacturers. Our decoration team advises on the most effective and cost-efficient combination for your design.
Which method has the best wash durability?
Sublimation has the best long-term durability because the colour is part of the fabric. Plastisol screen printing is a close second. DTG requires correct wash care (inside-out, cold wash) for maximum durability.