Apparel printing is the process of applying graphics, text, or designs onto garments using various techniques like screen printing, DTG, or sublimation. It’s widely used for custom t-shirts, merchandise, and branded clothing. The best method depends on your design, order volume, fabric type, and budget.

Why Apparel Printing Is So Popular (and Profitable)

The demand for custom clothing is booming. Thanks to platforms like Shopify, Etsy, and Printful, nearly anyone can launch a mini clothing line from home. In fact, the custom t-shirt printing market is projected to reach \$7.5 billion globally by 2031, according to Allied Market Research.

Here’s why it’s growing so fast:

  • Low startup costs: You don’t need a factory or warehouse — you can start with a laptop.
  • High demand: Businesses, influencers, and even schools want branded apparel.
  • Creative control: Design what you love, sell what you believe in.
  • Print-on-demand services: You don’t need to keep inventory or deal with shipping.

With the right method and tools, you can turn a simple design into a product people actually want to wear — and pay for.

The Main Goal of This Guide

If you’re wondering:

  • “Which printing method is best for my t-shirt design?”
  • “How much will it cost to start printing clothes?”
  • “Should I do it myself or use a service?”

You’re in the right place.

This guide breaks down every major apparel printing technique, shows you how to pick the right one, and walks you through your options — whether you’re printing at home, outsourcing, or starting a print-on-demand clothing brand.

We’ll also cover key tools, real-life examples, and smart tips to save money and avoid common mistakes.

Key Terms You Should Know

Before we get deeper, let’s clear up some common apparel printing terms:

  • Screen Printing – A classic method that uses mesh screens to press ink into fabric. Great for bulk orders and bold designs.
  • DTG (Direct-to-Garment) – A modern digital method that prints ink directly onto clothes, like a paper printer. Best for detailed designs and small batches.
  • Sublimation – A heat-based method that turns ink into gas and bonds it with polyester. Often used for sportswear or full-coverage prints.
  • Heat Transfer Vinyl (HTV) – A method where designs are cut from colored vinyl and pressed onto garments with heat.
  • Print-on-Demand (POD) – A service that prints and ships products only when a customer places an order. Great for new brands or low-risk testing.

Understanding these core printing methods will help you make better decisions, avoid wasted money, and get the results you want.

Understanding the Most Popular Apparel Printing Methods

When it comes to apparel printing, choosing the right method is everything. Each technique has its own benefits, limitations, and ideal use cases. Whether you’re printing 500 shirts for a concert or just one for your Etsy shop, knowing your options can save you time, money, and frustration.

Below, we break down the most common apparel printing methods used today — in simple terms — so you can choose the one that works best for your project or business.

Screen Printing: The Industry Standard for Bulk Orders

Screen printing is one of the oldest and most reliable methods for printing on clothing. It involves creating a custom mesh stencil (called a screen) for each color in your design. Ink is pushed through the screen onto the fabric, layer by layer.

Best For:

  • Large batches (50+ items)
  • Simple designs with limited colors
  • Bold, vibrant prints that last

Pros:

  • Super durable and long-lasting
  • Great for cotton fabrics
  • Low cost per unit for bulk orders

Cons:

  • Not ideal for small orders
  • Expensive setup (one screen per color)
  • Limited detail for complex designs

Example Use: A school orders 200 matching custom t-shirts for a fundraiser — screen printing is the most cost-effective and durable choice.

Direct-to-Garment (DTG): Digital Printing for Small Runs

Direct-to-garment printing, or DTG, works like an inkjet printer — but for clothes. It sprays water-based ink directly onto fabric using a special printer. This allows for full-color, high-detail designs, even with gradients or photographs.

Best For:

  • Small batch orders (1–30 pieces)
  • Detailed designs with lots of color
  • Print-on-demand businesses

Pros:

  • No setup fees — print one shirt at a time
  • Excellent for detailed artwork and color blending
  • Easy to start with minimal equipment

Cons:

  • Works best on 100% cotton
  • Not as durable as screen printing
  • Slower for bulk production

Example Use: An artist opens an Etsy store and sells one-off art tees — DTG lets them print as orders come in, without holding inventory.

Heat Transfer Vinyl (HTV): Best for Home Crafters and Personalization

HTV uses cut vinyl designs that are heat-pressed onto fabric. It’s common for crafters using tools like Cricut or Silhouette machines. You cut your design from colored vinyl, then apply it to a shirt using heat and pressure.

Best For:

  • DIY projects or home-based businesses
  • Names/numbers on jerseys or uniforms
  • Small, simple designs

Pros:

  • Inexpensive setup
  • Perfect for customizing one piece at a time
  • Good for polyester and blended fabrics

Cons:

  • Time-consuming for bulk orders
  • Limited in color detail (one color per layer)
  • Not ideal for photo-quality prints

Example Use: A mom makes custom birthday shirts for her kids — HTV gives her full creative control on a budget.

Sublimation Printing: For All-Over Prints and Polyester Fabrics

Sublimation is a heat-based process that turns ink into gas, bonding it with synthetic fibers like polyester. This method produces vibrant, long-lasting, full-coverage designs — perfect for sportswear or all-over prints.

Best For:

  • 100% polyester garments
  • All-over prints
  • Performance wear and athletic gear

Pros:

  • Bright, permanent colors
  • Doesn’t crack or peel
  • Great for moisture-wicking fabrics

Cons:

  • Only works on light-colored polyester
  • Not compatible with cotton
  • Specialized equipment required

Example Use: A startup launches a line of custom activewear — sublimation gives them full design flexibility on synthetic fabrics.

Print-on-Demand (POD): Easiest Way to Launch a Clothing Brand

Print-on-demand services like Printful, Printify, or Teespring let you upload a design and sell products without ever touching inventory. When someone places an order, the product is printed and shipped automatically.

Most POD platforms use DTG or sublimation depending on the product.

Best For:

  • Online stores and influencers
  • Test marketing new designs
  • Passive income with minimal setup

Pros:

  • No upfront inventory or equipment
  • Easy to scale
  • Integrates with Shopify, Etsy, etc.

Cons:

  • Lower profit margins
  • Less control over quality and fulfillment speed
  • Limited product customization

Example Use: A YouTuber launches a merch line through Printful — they upload a logo, and Printful handles everything from printing to shipping.

How to Choose the Best Apparel Printing Method for Your Needs

By now, you know there are several ways to print on apparel — from screen printing to direct-to-garment (DTG) to heat transfer and sublimation. But how do you decide which one is right for you?

To help you choose, we’ll compare each apparel printing method based on cost, speed, quality, durability, and best use cases. Whether you’re an artist launching your first product or a business printing hundreds of uniforms, this breakdown will give you clear answers.

Side-by-Side Comparison of Printing Methods

Here’s a simple table to show how the top printing methods stack up:

Method Best For Setup Cost Per-Unit Cost Durability Detail & Color Speed for Bulk
Screen Printing Bulk orders, bold logos High Low Excellent Limited (flat colors) Fast
DTG Printing Small runs, detailed art Low–Medium Medium Good High (photos, gradients) Slow
HTV (Vinyl) Personalization, DIY Low Low–Medium Good Moderate (limited colors) Slow
Sublimation Sportswear, full-print Medium Medium Excellent Very High Medium
Print-on-Demand E-commerce, testing ideas $0 Higher Varies High (depends on provider) N/A (on-demand)

 

Cost Breakdown: What to Expect

Let’s go deeper into startup costs and per-unit pricing, since this is often the deciding factor for beginners and small businesses.

Screen Printing Costs

  • Setup: $150–$500 (for screens, emulsion, and equipment)
  • Per Shirt (bulk): $2–$6 (with larger batches lowering the price)
  • Pro Tip: Costs drop significantly at 100+ units. Not ideal for single pieces.

DTG Costs

  • Setup: As low as $0 with POD services; owning a DTG printer costs $10,000+
  • Per Shirt: $8–$15 depending on design size and provider
  • Pro Tip: Ideal for designs with full-color details and low quantity orders.

HTV Costs

  • Setup: $200–$400 (Cricut/Silhouette machine + materials)
  • Per Shirt: $4–$7 including vinyl and shirt
  • Pro Tip: Great for beginners who want hands-on control at home.

Sublimation Costs

  • Setup: $300–$800 for printer and heat press
  • Per Shirt: $6–$10 (depends on garment type and coverage)
  • Pro Tip: Best for 100% polyester garments and bright, detailed prints.

Print-on-Demand Costs

  • Setup: Free (designs only)
  • Per Shirt (with profit margin): $13–$20
  • Pro Tip: Lower profits, but zero risk — ideal for testing products or scaling passively.

Real-World Use Cases (and What to Avoid)

Let’s take a closer look at practical situations and which printing method fits best:

Launching a Clothing Brand

  • Best Method: Start with print-on-demand or DTG to test your designs without big investment.
  • Why: Low risk, fast setup, and no need to buy inventory.

Corporate or Event T-Shirts

  • Best Method: Screen printing wins here.
  • Why: It’s cost-effective for large batches and provides consistent quality.

Artistic Tees with Full-Color Designs

  • Best Method: DTG printing
  • Why: You can print detailed artwork, shading, and gradients without sacrificing quality.

Athletic or Sports Apparel

  • Best Method: Sublimation
  • Why: It bonds with polyester, making it ideal for breathable, performance fabrics.

Names and Numbers on Jerseys

  • Best Method: HTV
  • Why: Quick personalization and small-batch flexibility make this perfect for sports teams.

Durability and Washability: What Lasts the Longest?

Durability matters. No one wants a shirt that fades or peels after one wash.

  • Screen printing offers the longest-lasting prints when done correctly.
  • Sublimation is permanent — it literally becomes part of the fabric.
  • HTV holds up well but can peel over time with frequent washing.
  • DTG is decent, but ink can fade slightly faster than screen prints.
  • Print-on-demand durability depends on the vendor — quality can vary.

Tip: Always wash printed apparel inside out in cold water, and hang dry when possible. This extends the life of the print.

Avoiding Common Mistakes

Many beginners lose money by choosing the wrong method for the wrong project. Here’s how to avoid that:

  • Don’t use DTG for large event orders — it’s too slow and expensive.
  • Don’t choose sublimation for cotton tees — it won’t work well.
  • Avoid screen printing for one-off designs — the setup costs don’t make sense.
  • Don’t rely on cheap POD vendors for high-volume sales — quality and shipping time can hurt your brand.

Now That You Know the Methods – What’s Next?

By now, you’ve learned how the major apparel printing techniques work, their pros and cons, and how they compare in real-world situations. So, what’s the next step?

It’s time to apply what you’ve learned and take action.

This section will guide you through how to choose your path, set up your first project, and avoid common roadblocks. Whether you’re looking to start a clothing brand, make custom shirts for an event, or test your creative side hustle, here’s how to begin.

Step 1: Define Your Goals Clearly

Before picking a method, get specific about what you’re trying to achieve. Ask yourself:

  • Am I printing 1 shirt or 100?
  • Is this for business, branding, or fun?
  • Do I want to print at home, or let someone else handle it?
  • Do I need fast turnaround, or can I wait?

Your answers will guide every decision moving forward.

Examples:

  • If you’re starting an online store and want to test product ideas: Print-on-demand is ideal.
  • If you’re making 200 shirts for a company retreat: Screen printing will be your best option.
  • If you want to create custom designs from your bedroom: DTG or HTV will give you full control.

Step 2: Choose Your Tools or Partners

Depending on your goals and printing method, you’ll either need DIY equipment or a reliable printing partner.

If You’re Printing at Home:

You’ll need tools like:

  • A heat press or DTG printer
  • A vinyl cutter (like Cricut) for HTV
  • Design software (Canva, Adobe Illustrator, GIMP)

Starter tip: Start small. Many crafters launch from home with under \$500 in gear.

If You’re Using a Print-on-Demand Service:

Choose from platforms like:

  • Printful (great for t-shirts, hoodies, mugs)
  • Printify (wide product selection and global fulfillment)
  • Teespring (good for creators and influencers)
  • Gelato, SPOD, or Apliiq (for premium POD)

Pro tip: Order test samples before launching to check quality and print accuracy.

If You’re Outsourcing to a Local Print Shop:

Search for:

  • “Custom screen printing near me”
  • “T-shirt printing services [your city]”
  • Check reviews, turnaround times, and bulk pricing

Step 3: Prepare Your Design

Your design will make or break the final product — even with the best printing method.

Here’s how to get it right:

  • Use high-resolution artwork (300 DPI is standard)
  • Save files in vector or transparent PNG format
  • Make sure colors are clearly defined, especially for screen printing
  • For DTG or sublimation, make use of full color and gradients
  • For HTV, keep it simple — fewer shapes and solid colors work best

If you’re not a designer, tools like Canva, Placeit, or hiring on Fiverr can help you get professional results quickly.

Step 4: Run a Small Test First

Don’t go all-in before you’ve tested your process. Print just a few pieces to:

  • Check design placement
  • Test fit and fabric quality
  • Review printing durability after washing
  • Get feedback from real people

Tip: Wear your own samples and promote them on social media to test demand organically.

Final Thoughts: You’re Closer Than You Think

Apparel printing is one of the most accessible ways to build a brand, express yourself creatively, or create products people love. With today’s tools and services, you don’t need a huge budget or a team — just a great design, a clear plan, and the right printing method.

If you’re still unsure where to begin, start small. Launch one product. Print one shirt. Try one method. The experience you gain from that single step will teach you more than research ever could.

FAQ

What’s the difference between DTG and screen printing?

DTG (Direct-to-Garment) prints designs directly onto fabric using a digital printer, making it ideal for small orders and detailed artwork. Screen printing uses stencils and ink layers, making it better for bulk printing and solid-color designs. DTG is faster to set up, while screen printing offers lower costs at high volumes.

Can I print on polyester garments?

Yes, but not all printing methods work well on polyester. Sublimation printing is best for 100% polyester and produces vibrant, long-lasting results. Avoid DTG on polyester, as the ink may not absorb properly.

How much does it cost to start an apparel printing business?

Starting an apparel printing business can cost anywhere from \$500 to over \$10,000, depending on the method and equipment. HTV and heat press setups are cheaper for beginners, while DTG or screen printing require more upfront investment. Always budget for design software, blanks, and marketing tools.

Is print-on-demand profitable in 2025?

Yes, print-on-demand (POD) can be profitable in 2025, especially for niche markets and online creators. Success depends on strong designs, smart pricing strategies, and effective marketing. Keep in mind that profit margins are lower than bulk printing, so volume and branding matter.

Which printing method is most eco-friendly?

Sublimation and water-based DTG inks are among the most eco-friendly apparel printing methods. They use less waste and fewer chemicals than traditional screen printing. Look for OEKO-TEX® certified inks and on-demand models to reduce environmental impact.

Ready to Start Printing? Here’s Your Next Step

If you’re serious about getting started, here’s what you can do next:

Explore our beginner’s guide to starting a clothing brand. Compare the best print-on-demand platforms or download our free Apparel Printing Starter Kit with checklists, templates, and tool recommendations