Is screen printing the best for bulk orders?

Yes, screen printing is often the most cost-effective and durable method for large bulk orders of apparel. While setup costs can be higher at the start, the per-unit price drops sharply when printing large quantities, making it a top choice for businesses, schools, and events that need the same design printed at scale.

Understanding Screen Printing

What Is Screen Printing?

Screen printing, also known as silkscreen printing, is one of the oldest and most popular ways to print graphics on fabric. It works by pushing ink through a stencil-like screen directly onto a shirt, hoodie, or tote bag. Each color in the design uses its own custom screen, which is why this method shines when printing a large number of items with the same design.

If you’ve ever worn a custom t-shirt from a fundraiser or a band tour, chances are it was made using screen printing. This method has been a staple in the apparel printing industry for decades because it delivers rich, long-lasting colors and professional results.

How the Process Works (Frames, Stencils, Inks)

Let’s break it down:

  1. Design Creation You start by preparing your artwork or logo, usually in vector format. Each color in the design is separated digitally.
  2. Screen Setup A mesh screen is stretched tightly over a frame. Then, a light-sensitive emulsion is applied. The design is printed on a transparent film and placed over the screen. After it’s exposed to light, the emulsion hardens except where the design blocked it. The unhardened areas are washed away, creating an open stencil.
  3. Printing The prepared screen is placed on the item (like a t-shirt), and ink is pushed through using a squeegee. This is repeated for each color and garment.
  4. Drying After printing, the ink needs to be heat-cured. This helps the design stick to the fabric permanently, making it resistant to fading or peeling.
  5. Cleanup Screens are washed and reused, or reclaimed for new designs.

This method works great when you’re printing simple, bold graphics in 1–4 colors across dozens or hundreds of items.

Ideal Materials for Screen Printing

One of the biggest advantages of screen printing is how well it works with different fabric types, especially:

  • 100% Cotton: Holds ink well, feels soft, and produces vibrant prints.
  • Cotton-Poly Blends: Common in t-shirts and hoodies; results still look great.
  • Canvas & Tote Bags: Durable surfaces make them ideal for bold logos.
  • Polyester (with care): Needs special inks and lower heat but still printable.

Screen printing tends to perform best on flat surfaces and medium to thick materials. If you’re printing on nylon, silk, or stretchy sportswear, other methods might be more suitable (we’ll cover that in a later section).

Benefits of Screen Printing for Bulk Orders

When it comes to printing large quantities of custom apparel, screen printing often leads the pack. This method isn’t just popular by chance—it’s built to scale. Below are the biggest reasons why screen printing remains a top choice for bulk printing.

Low Cost Per Unit at High Volumes

One of the strongest benefits of screen printing is the low cost per unit when you’re printing in bulk. Here’s why:

  • Setup costs include making the screens for each color. While this upfront cost is fixed, it gets spread across the entire order.
  • The more you print, the less you pay per shirt.

For example:

  • 20 shirts might cost \$10 each.
  • 200 shirts? That could drop to \$4–\$5 per shirt for the same design.

This makes screen printing perfect for:

  • Corporate uniforms
  • Event merchandise
  • School fundraisers
  • Bulk brand promotions

The more items you order, the more affordable screen printing becomes compared to methods like direct-to-garment (DTG) or heat transfer.

Long-Lasting Prints with High Durability

Durability is a must when you’re printing gear for repeated use—think sports teams, workwear, or college apparel. With screen printing, you’re getting:

  • Thick, vivid layers of ink that soak into the fabric.
  • Heat-cured finishes that prevent cracking, peeling, or fading.
  • Wash resistance — prints often last for 50+ washes with proper care.

Compared to heat transfer vinyl, which may peel after several washes, or DTG, which can fade over time, screen printing holds up far better on the field, in the workplace, or in the laundry room.

If you’re printing for customers or staff who wear the item often, print longevity matters. That’s where screen printing gives your investment the best return.

Vibrant Colors and Opacity on Dark Fabrics

Have a design with bold reds, bright whites, or neon greens? Screen printing can handle it—especially on dark garments, where other methods can struggle.

Here’s how screen printing stands out:

  • Opaque ink layers help colors stand out against black or navy shirts.
  • You can apply underbase layers (like a white background) to make bright colors pop.
  • Unlike DTG, which can look muted on darker fabric, screen prints stay crisp and bold.

If your brand has strong visual identity or your design includes high-contrast artwork, screen printing delivers eye-catching results that people notice.

Efficiency in Mass Production

Time matters. And if you’re ordering hundreds of shirts for an event or retail drop, you need speed and consistency.

With screen printing, once the screens are ready:

  • Printing is fast — up to 1,000 shirts a day on automated presses.
  • Every shirt in the batch looks uniform, making this ideal for bulk production.
  • It’s easy to print on multiple garment types (e.g., hoodies, tees, bags) using the same design.

This makes screen printing a great fit for:

  • Seasonal merch drops
  • Conference giveaways
  • Retail stock orders

Want to keep your brand consistent and stay on schedule? Screen printing delivers—on quality and turnaround time.

When Screen Printing May Not Be the Best Fit

While screen printing shines in many bulk scenarios, it’s not always the perfect match. Certain projects demand more flexibility, shorter runs, or fine-detail printing that screen printing can’t easily deliver.

Let’s look at when it may be better to explore alternative printing methods like DTG (Direct-to-Garment), heat transfer, or sublimation.

Setup Time and Initial Costs

One of the main downsides to screen printing is the setup process. Each color in your design needs:

  • A separate screen
  • A precise alignment process (called registration)
  • Time for exposing, washing, and drying screens

That means:

  • Even if you’re only printing 10 shirts, you’ll still pay for all the screens.
  • Smaller orders may feel overpriced because setup costs don’t scale down.

So, if you only need a small quantity or want one-off pieces, consider methods like:

  • DTG printing, which doesn’t need screen setup
  • Heat transfers, which work well for low-quantity runs

For example, if you’re launching a custom gift shop or printing sample pieces, screen printing may not offer the best value upfront.

Limited to Few Design Variations per Batch

With screen printing, every design variation requires:

  • A new set of screens
  • A new print setup
  • More labor and time

This becomes a challenge if:

  • You want each shirt to have different names or numbers (like jerseys)
  • You’re printing multiple color variations for the same design
  • Your artwork includes lots of photographic details or gradients

In contrast, DTG printing or digital heat transfers handle multi-design batches better since they print directly from the digital file.

So if your order includes lots of personalization, screen printing may slow you down and cost more.

Unsuitable for Small-Scale or Photographic Detail

If you’re looking to print detailed portraits, photo-realistic artwork, or fine gradients, screen printing has limits:

  • Screens struggle with tiny color shifts
  • Halftones can mimic gradients, but the result is often less sharp
  • Designs with more than 5 colors become time-consuming and costly

On the other hand, DTG printing offers:

  • Full-color prints with subtle shading
  • Better reproduction of photos and complex designs

That makes DTG a better fit for:

  • Art-driven apparel brands
  • Low-volume photo shirts
  • On-demand printing platforms

So, if your design is rich in texture, layers, and digital art, screen printing may not give the clarity you need.

Comparison with Other Printing Methods

Choosing the best method for your bulk order means understanding how screen printing compares to other popular options. Let’s break it down by features like cost, quality, flexibility, and ideal use cases.

Screen Printing vs. Direct-to-Garment (DTG)

DTG printing uses a digital printer to apply ink directly onto fabric, much like an inkjet printer on paper.

When DTG wins:

  • Great for small runs (even one-offs)
  • Perfect for full-color or photo designs
  • Works well with complex artwork and gradients

Where screen printing beats DTG:

  • Lower per-unit cost for large quantities
  • Better durability and wash resistance
  • Faster production once setup is complete

Bottom line: Choose DTG for low-volume, highly detailed or photo-like prints. Stick with screen printing for large batches and bold designs.

Screen Printing vs. Heat Transfer Vinyl (HTV)

Heat transfer vinyl involves cutting out a design and pressing it onto fabric with heat.

When HTV works best:

  • Custom names or numbers (e.g., team jerseys)
  • Fast turnaround for small batches
  • Works on odd materials like nylon or spandex

When screen printing is better:

  • Larger runs of the same design
  • Greater color vibrancy and ink penetration
  • Better feel and durability after washing

Bottom line: Use HTV for personalization and specialty materials. Go with screen printing when printing the same design across many pieces.

Screen Printing vs. Sublimation

Sublimation printing uses heat to turn dye into gas, which bonds with synthetic fabric.

When sublimation is strong:

  • Polyester garments (especially white or light-colored)
  • Full-coverage designs that cover the entire shirt
  • Extremely soft, breathable feel

Where screen printing excels:

  • Works better on cotton and cotton blends
  • Handles darker fabrics better
  • Provides bold, thick prints

Bottom line: Choose sublimation for all-over prints on polyester. Choose screen printing for bold, durable logos on cotton or blended garments.

Performance by Fabric Type, Speed, and Cost

Method Best For Fabric Type Turnaround Cost at Scale
Screen Printing Bulk orders, vibrant logos Cotton, blends, canvas Fast (after setup) Low
DTG Printing Photo-quality, small runs Cotton Moderate High
Heat Transfer Vinyl Custom names, short runs Most fabrics Fast Moderate
Sublimation Full-shirt designs Polyester Fast Moderate-High

 

Final Verdict: When Is Screen Printing the Right Choice?

Choose screen printing if:

  • You’re ordering 50+ pieces of the same design
  • You want bold, bright colors (especially on dark fabric)
  • You need durability and wash-proof quality
  • Your timeline allows a 2–5 day setup window

Avoid screen printing if:

  • You’re doing one-offs or personalized names
  • You need photorealistic detail
  • You’re printing on polyester or spandex-heavy items

Want to make your choice easier? Use our free printing method selector to compare options based on your quantity, fabric, and design style.

Call to Action: Ready to Print in Bulk?

Looking to print shirts, hoodies, or tote bags for your brand, event, or team?

Use our cost comparison calculator to determine the most cost-effective method for your bulk order. Get matched with vetted screen printing providers who fit your timeline and budget. Learn more with our guides on how to price bulk custom apparel orders, eco-friendly printing methods, and what to include in your print-ready file.

FAQs

Is screen printing cheaper for bulk orders? 

Yes, screen printing becomes cheaper per item as your order size increases. The setup cost is spread across all units, making it ideal for bulk printing.

How long does screen printing take for 100+ shirts?

 Most bulk screen printing orders of 100+ shirts take about 3 to 7 business days. Time depends on the design complexity and printer availability.

What are the best fabrics for screen printing? 

The best fabrics for screen printing are 100% cotton, cotton-poly blends, and canvas. These materials hold ink well and produce crisp, durable prints.

Can I use multiple designs in a bulk screen printing order?

You can, but each design requires a separate setup, which adds to the cost and time. Screen printing works best for large batches of the same design.

Is screen printing eco-friendly for large-scale runs? 

Yes, especially when using water-based inks and sustainable fabrics. Look for print shops that follow eco-friendly practices to reduce waste and water use.