Direct-to-Garment (DTG) printing is a modern digital method for applying full-color designs directly onto textiles using specialized inkjet technology. Unlike screen printing, which relies on physical screens and stencils, DTG uses a printer to spray water-based ink onto fabric, similar to how a document printer works.

The result is a highly detailed, vibrant print that becomes part of the fabric, delivering softness and precision that other methods often struggle to match—especially for complex, color-rich designs.

How DTG Printing Works

DTG printing involves a multi-step digital-to-physical process designed to ensure accurate and durable results. Here’s how it works:

1. Design Preparation

The artwork is prepared using graphic design software. High-resolution files (typically 300 DPI or more) in formats like PNG or TIFF are preferred. The file is loaded into a Raster Image Processor (RIP) software, which prepares it for output by separating color layers and aligning ink drop data.

2. Pretreatment (For Dark Garments)

If printing on dark fabrics, the garment must be pretreated with a special solution. This treatment:

  • Helps white ink sit on top of the fabric rather than soaking in.
  • Improves color brightness and wash durability.
  • Prevents bleeding and ink migration.

The pretreatment is applied either manually or using automated pretreatment machines. After application, the fabric is dried using a heat press.

3. Printing Process

Once the garment is ready, it is placed flat onto the printer platen. The printer’s inkjets then deposit the design directly onto the garment, layer by layer. If the shirt is dark, a white underbase is printed first, followed by color layers.

4. Curing the Ink

After printing, the garment is heat-cured to bond the ink to the fibers. This is done using a heat press or conveyor dryer at a specific temperature and time setting (usually 320°F for 90-180 seconds, depending on ink and fabric type).

What Materials Work Best with DTG?

DTG is optimized for printing on 100% cotton or high-cotton blends (at least 80% cotton). Cotton’s absorbent, natural fibers hold water-based inks well and produce sharp, vibrant images.

Recommended Fabrics:

  • 100% combed ringspun cotton
  • Cotton/poly blends (60/40 or 80/20)
  • Tri-blends with high cotton content

Not Ideal For:

  • 100% polyester (especially moisture-wicking)
  • Nylon or spandex
  • Synthetic, coated, or water-resistant fabrics

For poly-based fabrics, dye sublimation or screen printing may yield better results.

Benefits of DTG Printing

1. Full-Spectrum Color and High Detail

DTG handles photorealistic designs, gradients, and minute details effortlessly. You’re not limited by the number of colors or design complexity. This makes DTG ideal for:

  • Photographic prints
  • Illustrations and artwork
  • Multi-color company logos

2. Low Setup Time

Because DTG requires no physical setup like screens or films, you can start printing within minutes of uploading a design. This drastically reduces lead times for small or urgent orders.

3. Cost-Effective for Small Runs

DTG offers fixed per-unit pricing regardless of quantity. This contrasts with screen printing, where low-volume orders are penalized by setup costs.

Example:

  • Screen printing a 3-color design on 10 shirts might cost \$20 per shirt.
  • The same design via DTG may cost \$8–\$12 per shirt, without setup fees.

4. Eco-Conscious Process

DTG uses water-based, non-toxic inks and produces minimal waste. Many modern DTG printers are certified to OEKO-TEX® standards, ensuring the print is safe for children and eco-friendly.

5. Soft-Hand Feel

DTG prints do not create a thick plastic-like layer. The ink absorbs into the fibers, resulting in a smooth, breathable surface. This enhances wearer comfort, particularly for fashion or retail apparel.

Limitations of DTG Printing

1. Less Economical for Bulk Orders

For high-volume printing (e.g., 500+ shirts), DTG is often more expensive per unit than screen printing. This is due to:

  • Slower print speeds (typically 1–5 minutes per shirt)
  • Consumable costs (inks, maintenance kits)

Screen printing, which reuses screens for every shirt, spreads costs more efficiently at scale.

2. Color Output on Dark or Synthetic Fabrics

Dark fabrics require white underbase layers and perfect pretreatment to maintain print clarity. Without it, the ink can soak into the garment and appear faded or discolored. Similarly, synthetic fibers resist absorption, leading to poor ink adhesion.

3. Wash Durability Variability

Modern DTG prints can last 40–50 washes if properly cured and cared for. However:

  • Incomplete curing can cause premature fading or cracking.
  • Harsh washing (hot water, aggressive detergents, or high heat drying) can reduce lifespan.

Compared to plastisol screen prints—which may last over 100 washes—DTG requires more careful care.

4. Maintenance Requirements

DTG printers need daily or weekly cleaning and periodic part replacements (nozzles, capping stations). Inks can clog if left idle, making consistent use or proper storage essential.

DTG Printing vs. Other Methods

DTG vs. Screen Printing

Feature DTG Printing Screen Printing
Setup Time Minutes Hours (per color screen setup)
Color Flexibility Unlimited, full-color Limited (charged per color)
Best Use Case Short runs, custom, artistic designs High-volume, simple, bold prints
Fabric Compatibility Cotton and blends Wide range (including polyester)
Wash Durability Moderate (40–50 washes) Excellent (100+ washes with plastisol)
Unit Cost (Low Qty) Low High
Unit Cost (High Qty) High Low

DTG vs. Heat Transfer Vinyl (HTV)

  • HTV is better for blocky, single-color designs or performance fabrics.
  • DTG provides more comfort and breathability, especially for full-color prints.

DTG vs. Dye Sublimation

  • Sublimation excels on polyester and white/light garments.
  • DTG dominates for cotton and dark apparel.

Ideal Scenarios for Using DTG Printing

1. On-Demand Ecommerce

Print-on-demand (POD) services rely heavily on DTG for rapid, scalable fulfillment of personalized orders. DTG integrates with platforms like:

  • Shopify
  • Etsy
  • WooCommerce
  • Printful
  • Printify

No inventory is required. Items are printed only when sold.

2. Fashion and Streetwear Brands

Many independent brands choose DTG for its softness and ability to print bold, artistic visuals with minimal commitment. DTG lets designers prototype designs and drop limited editions without upfront production costs.

3. Corporate Events and Giveaways

Short-run branded apparel for trade shows, team-building, or internal gifting can be efficiently produced using DTG.

4. Artists and Illustrators

DTG captures every nuance of hand-drawn illustrations, digital art, or photography—making it ideal for wearable artwork.

5. Local Print Shops

DTG adds versatility to brick-and-mortar print shops, enabling them to fulfill walk-in orders, personal gifts, and samples without overhauling operations.

How to Ensure High-Quality DTG Results

To optimize output, follow these best practices:

  • Use high-resolution artwork (at least 300 DPI).
  • Choose quality garments (combed cotton or DTG-certified brands).
  • Control humidity in the print room to prevent nozzle clogging.
  • Follow curing instructions exactly to ensure durability.
  • Test pretreatment levels on different garments before full runs.

 

Advanced Guide to DTG Printing: Workflow, Costs, and Innovations

DTG Printing Workflow: Step-by-Step Process

Understanding the complete workflow ensures consistent quality and operational efficiency. Below is a breakdown of a standard DTG production process.

1. Garment Selection

Choose garments with:

  • High cotton content (100% combed ringspun cotton recommended)
  • Smooth surface for fine detail
  • Certified DTG compatibility (e.g., Bella+Canvas, Next Level, Gildan Softstyle)

2. Pretreatment Application

Pretreatment is essential for dark-colored garments and complex designs requiring a white base. Common methods:

  • Manual Spraying: Ideal for very low volumes.
  • Automated Pretreatment Machines: Provide consistent coverage and reduce labor.

Important considerations:

  • Shake pretreatment solution thoroughly.
  • Apply evenly—too much causes staining, too little causes ink washout.
  • Dry the garment completely before printing.

3. RIP Software Configuration

RIP (Raster Image Processor) software prepares artwork by:

  • Managing ink layers
  • Calibrating color profiles
  • Adding underbase where needed
  • Estimating ink consumption

Popular RIP software includes:

4. Printing Execution

Load the garment onto the printer platen. Align it properly to avoid skewed prints. Ensure:

  • No wrinkles or lint (which cause ink spray errors)
  • Correct platen height (typically 2–3 mm below the print head)

The print duration depends on:

  • Design complexity
  • Resolution settings
  • Machine model (entry-level vs industrial)

Average print time: 2–6 minutes per shirt

5. Ink Curing

Curing bonds the ink to the fabric. This is critical for wash durability.

  • Heat Press: Set to 320°F (160°C) for 90–180 seconds.
  • Conveyor Dryer: More efficient for higher volumes.

Use parchment paper or silicone sheets to prevent ink from sticking to the press.

6. Quality Inspection and Packaging

Final steps:

  • Inspect print alignment, ink coverage, and color accuracy.
  • Check for pretreatment stains or curing marks.
  • Package in a way that prevents smudging or reactivation of ink.

DTG Equipment Overview

Entry-Level DTG Printers

Good for startups, small shops, or limited budgets. Examples:

  • Epson SureColor F2100
  • Brother GTX Pro Bulk
  • Ricoh Ri 1000

Pros:

  • Affordable ($10,000–$20,000)
  • Reliable for low-to-mid volumes
  • Easy to learn and operate

Cons:

  • Slower print speed
  • Higher ink cost per print
  • Limited scalability

Mid-Range and Industrial DTG Printers

For production-level volumes or print-on-demand integration.

  • Kornit Atlas or Breeze
  • Aeoon Kyo Series
  • Polyprint TexJet Echo2

Pros:

  • Fast print speeds (20–50 shirts/hour)
  • Bulk ink systems
  • Advanced print heads (e.g., Ricoh Gen5)

Cons:

  • Costly ($50,000–$250,000+)
  • Higher maintenance demands
  • Requires workflow optimization

Cost Breakdown of DTG Printing

Startup Costs

Item Cost Estimate
Entry-Level Printer $15,000–$20,000
Pretreatment Machine $2,000–$5,000
Heat Press $500–$2,000
RIP Software $500–$1,500
Cleaning Supplies + Accessories $500–$1,000
Total Startup Range $18,500–$29,500

Operating Costs Per Shirt

Expense Light Shirt Dark Shirt
Blank Garment $2.00–$4.00 $2.00–$4.00
Ink $0.50–$1.00 $1.00–$2.50
Pretreatment N/A $0.25–$0.50
Labor + Utilities $1.00–$1.50 $1.00–$1.50
Total Cost $3.50–$6.50 $4.50–$8.50

Profit Margin Potential

  • Retail price per shirt: $20–$35
  • Typical markup: 200%–400%
  • Best profits come from custom, high-value designs (e.g., limited runs, personal gifts)

Maintenance and Longevity of DTG Systems

Daily Maintenance Tasks

  • Nozzle checks
  • Printhead cleaning
  • Wiper blade cleaning
  • Ink agitation (manual or automated)

Neglecting these tasks leads to:

  • Clogged nozzles
  • Banding on prints
  • Increased waste and downtime

Monthly/Quarterly Maintenance

  • Replace dampers, capping stations, or ink lines as needed.
  • Clean waste ink tanks and lines.
  • Calibrate platen height and alignment.

Expected Lifespan

With proper care:

  • Entry-level printers: 3–5 years
  • Industrial printers: 7–10 years

Industry Trends in DTG Printing

1. Hybrid DTG/Screen Systems

Machines like the Kornit Avalanche HD6 blend DTG color with screen-printed white underbases for the best of both worlds. These offer:

  • Faster throughput
  • Sharper white prints
  • Lower ink costs

2. Automation and AI Workflow

  • RIP software now integrates AI to auto-optimize ink usage.
  • Cloud-based print queues sync with ecommerce orders for hands-free fulfillment.

3. Eco-Friendly Innovations

  • OEKO-TEX® certified inks and pretreatments are now standard.
  • Kornit and Brother emphasize reduced water use and carbon footprints in newer models.

4. Growth in Personalized Apparel

According to market research (Allied Market Research, 2024), the custom T-shirt printing market is expected to reach $10 billion by 2028, driven largely by DTG and POD models.

5. Sustainable DTG Startups

New entrants emphasize organic garments, biodegradable packaging, and circular fashion—trends that align with eco-conscious consumers.

Frequently Asked Questions (FAQs)

What is DTG printing best used for?

DTG printing is best for small-batch, full-color, and custom apparel. It excels at printing complex, detailed designs directly onto cotton garments without setup costs.

How durable is DTG printing?

Modern DTG prints last 40–50 washes with proper care. Washing in cold water and air drying can extend longevity. Fading may occur faster than plastisol screen prints if not cured correctly.

Does DTG work on polyester or synthetic fabrics?

No. DTG printing performs poorly on polyester. It’s optimized for cotton and cotton-blend materials. For synthetic fabrics, consider dye sublimation or screen printing.

Is DTG better than screen printing?

DTG is better for short runs and detailed, multicolor designs. Screen printing is more cost-effective for large batches and bold, simple prints.

Can I use DTG printing for print-on-demand services?

Yes. DTG is the primary technology for print-on-demand apparel businesses. It allows automated order processing without inventory or bulk production.

What is pretreatment in DTG printing?

Pretreatment is a coating applied to garments before printing, especially dark ones. It helps white ink sit on the fabric and improves ink adhesion and color vibrancy.

Final Summary: When Should You Use DTG Printing?

Choose DTG when you need high-detail, full-color prints on cotton garments in small quantities or on-demand. It’s ideal for ecommerce, custom artwork, and quick-turnaround jobs.

Avoid DTG for high-volume orders or synthetic fabrics. In those cases, screen printing or sublimation may offer better cost-efficiency or material compatibility.