Find the best print method for your project based on real cost data
DTG and screen printing are the two most popular t-shirt printing methods, but they excel in very different scenarios. This tool compares them head-to-head based on YOUR order details to show which method saves you money and delivers better results. Adjust the sliders below and see your personalized recommendation update in real time. Last updated: April 2026.
How to Use This Tool
1
Set your order quantity and number of design colors using the sliders
2
Choose your garment type, fabric color, and whether this is a one-time or recurring order
3
See the winner with cost breakdown, head-to-head scores, and break-even analysis
What you'll learn: Per-unit cost for each method, which wins for YOUR specific order, and the exact quantity where screen printing becomes cheaper than DTG.
Screen Printing ⓘInk pushed through stenciled mesh screens onto fabric
$9.80
per unit
Break-Even Point ⓘThe quantity where screen printing becomes cheaper per unit than DTG
1 unit500 units
Expert Tips
Break-Even Sweet Spot
Screen printing becomes cheaper than DTG at roughly 25-50 units for simple designs, this tool calculates YOUR exact break-even.
Unlimited Colors
DTG is the only method that can print photographic images with unlimited colors at no extra cost per color.
Recurring Orders
For recurring orders, screen printing wins big, screens are reusable, eliminating setup costs on reorders.
Sustainability
DTG uses water-based eco-friendly inks, a selling point if your customers care about sustainability.
Frequently Asked Questions
It depends on the design. DTG produces sharper photographic and gradient details because it works like an inkjet printer with millions of colors. Screen printing delivers more vibrant, opaque spot colors and a thicker ink deposit that really pops on dark garments. For logos with 1-3 solid colors, screen printing typically looks bolder. For complex artwork, DTG wins.
Typically between 25-50 units for simple 1-2 color designs, and 50-100 units for complex multicolor work. Screen printing has higher upfront costs ($25-40 per color for screens) but much lower per-unit costs, so it overtakes DTG as volume increases. Use the tool above to find your exact break-even point.
Yes, but it requires a white pretreatment layer sprayed onto the garment first, which adds cost ($1.50-2.50 extra per unit) and can sometimes leave a slightly stiffer feel. Screen printing also needs an underbase for dark garments, but the result tends to be more opaque. Both methods work on dark shirts, DTG just costs more for them.
Screen printing generally lasts longer: 50-100+ washes vs DTG's 30-50 washes before noticeable fading. Screen print ink sits on top of the fabric in a thicker layer, especially with plastisol inks. DTG ink absorbs into the fibers, giving a softer feel but less long-term vibrancy. Both benefit from washing inside-out on cold and hang drying.
DTG is usually better for small businesses starting out because there are no minimums, no setup costs, and you can print one shirt at a time. This means less inventory risk. As your volumes grow past 50+ units per design, transitioning to screen printing saves significant money per unit. Many successful brands use DTG for testing designs, then switch to screen printing for proven sellers.
DTG is generally more eco-friendly. It uses water-based CMYK inks with no harmful chemicals, produces zero wasted ink (only what's printed is used), and requires no screen cleanup chemicals. Traditional screen printing uses plastisol (PVC-based) inks and requires chemical solvents for screen cleaning. However, water-based screen printing inks are now available as a greener alternative.
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Per-unit pricing at every quantity, wash durability, setup fees, hand-feel, and the exact breakeven where screen printing overtakes DTG on cost.
Common questions
Which decoration method is most cost-effective for bulk orders?
Screen printing wins on cost-per-unit above 50 pieces with simple designs (1-4 ink colors). Per-unit cost drops sharply as quantity rises because the screen setup is amortized across the run.
Which decoration method is best for full-color photo designs?
DTG (direct-to-garment) handles unlimited colors and photographic detail with no per-color setup fee. DTF is similar but works on more substrates including blends and synthetics.
Which decoration method lasts the longest on workwear?
Embroidery and screen printing both pass 50+ industrial wash cycles per AATCC laundering standards. Embroidery wins on durability for high-friction garments like jackets, polos, and hats.
Built by Arklavo. We run Arklavo, a US-based custom apparel shop. We have shipped custom embroidery, DTG, and screen print to small business teams, ops managers, and HR managers across the US, with no minimum order and free shipping over $150. We built this tool from numbers we use on real quotes every week. Request a quote from our team when you are ready to talk pricing on your specific project.
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Conor Smart |
2026-06-09
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