DTF vs Screen Printing- Which is the Right Choice?

The textile printing industry is thriving, offering more options than ever to create premium-quality garments. If you want to learn about the best method to print a custom garment, you might find yourself confused between screen printing and Direct-to-Film transfers.

If choosing between the two is overwhelming you, we will give you a lowdown of what they are and how they work. So, let’s dive in.

What is DTF Printing?

DTF or Direct-to-Film printing is a method that prints the design onto a special film, which can be transferred onto the fabric using heat. The printer uses specially formulated ink that sticks to the film and is transferred onto the fabric using heat and pressure.

The DTF method, as a printing method, is highly versatile. With this, you can create highly detailed designs and vibrant colors. The design is first printed in reverse on the film, then coated with a powder adhesive that sticks to the ink. Once heated, the adhesive transfers the design onto the fabric. DTF works on polyester, cotton, and blended materials. The process is less labor-intensive in comparison to screen printing. Thus, it can be used for both small and large-scale production.

How does DTF Printing Work?

DTF has transformed the custom apparel industry, making it easier to turn digital designs into finished garments. Here is how it works.

1. Design Printed onto PET Film

The printing method starts with the printer being loaded with DTF inks. To apply the design onto the PET film directly, the printer uses water-based inks. Next, CMYK colors are printed onto a clear PET film, followed by a layer of white ink. The white ink acts as a base, making colors vibrant and opaque on dark or black fabrics.

2. Application of Adhesive Powder

While the white ink is still wet, thermal adhesive powder is applied, sticking only to the printed areas. This powder acts as a bonding agent for the fabric. Gently shake the film to remove any excess powder from unprinted areas. Not applying the powder can cause the DTF transfer not to stick to the fabric.

3. Bake and Cure

The film has to be heated to melt the adhesive powder into smooth glue. A specialized curing oven or a heat press held just above the film can be used. This step fuses the powder and wet ink into a stable transfer, ensuring the design remains durable and flexible after application.

4. Heat Press Transfer

The cured film is placed on the garment and pressed with heat and pressure, reactivating the adhesive so it bonds with the fabric fibers. This step is typically done at 300°F–325°F for about 15 seconds, creating a strong, lasting bond between the design and the material.

5. Hot/Cold Peel Film

Remove the PET film according to the media manufacturer’s instructions. Hot peel films are removed while still warm, while cold peel films must cool completely before peeling. Once removed, the design appears vibrant and sharp, with crisp edges and high opacity.

Pros and Cons of DTF Printing

Pros

• Environmentally-friendly ink
• No pre-treatment requirement for applying transfers
• Prints on synthetic, as well as natural fibers
• Designs pop on all colored backdrops

Cons

• Curing powder has to be kept cool
• Prints on the fabric can have a shiny finish, but not be soft enough
• Can’t produce special effects, such as metallic paint or glitter

What is Screen Printing?

Screen printing is a traditional method where ink is pressed through a mesh screen onto fabric. Each color requires a separate screen, making it ideal for simple, low-color designs produced in large quantities. Known for its durability, screen printing has remained a popular choice for decades.

For startups that have to order customized apparel in the same design in bulk, screen printing is the most affordable solution.

How does Screen Printing Work?

Being a reliable printing method, screen printing is still the standard choice for high-volume production. But it requires a proper physical setup before you start printing. Take a look at how  the screen printing method works.

1. Separate Design Colors

You cannot simply start printing with this method. First, you have to separate the design from the color layers using graphics software. Every color you print needs its own specific screen.

2. Make Screen

Coat the mesh screen with a light-sensitive emulsion and let it dry in a dark room. Next, expose the screen to UV light using the design as a stencil. Rinse away the unexposed emulsion to create open areas in the mesh where the ink can pass through.

3. Mix the Color and Ink

The inks are mixed manually to achieve the exact colors your customers want. They are thick enough to sit on top of the screen until you’re ready to press them through.

4. Layered Printing

Place the garment on the pallet and pull a squeegee across the screen to push the ink through the mesh. If the design has five colors, the process is repeated five times, with careful alignment of each layer.

5. Dry and Cure

Dry each color briefly before applying the next to avoid smears. After printing is complete, the garment is fully cured in a conveyor dryer at high heat.

Pros and Cons of Screen Printing

Pros

• Durable printing method
• Softer and smoother feel with the right paint
• Creates more special effects, like metallic paint and glitter
• Affordable when printed in bulk

Cons

• Requires cut and stencils for every design
• Needs a large investment in equipment
• Takes up a lot of space
• Not very adept at photo-realistic designs with multiple colors

Difference Between DTF and Screen Printing

If you are in the garment printing business, you should choose your printing method very carefully. However, you should consider various factors that can have a significant effect on the bottom line. Here is how the two printing methods differ from each other.

• Printing Quality and Durability

DTF delivers high-quality prints with vibrant colors and fine details. Its water-based inks bond well with fabric, producing sharp and durable results. However, durability depends on the fabric type and washing conditions. With proper care, DTF prints can last a long time, though they are generally less resistant to repeated wear and washing compared to screen printing.

Screen printing, on the other hand, creates highly durable prints. It uses thick and durable ink. Hence, it is a good choice for a design that has to withstand heavy wear, such as sportswear. In comparison to DTF, the print quality of screen printing might be a tad less detailed. With proper curing, it excels in terms of durability.

• Printing Complexity

DTF printing is ideal for complex designs, as it handles intricate details and photographic images with ease. Since each design is printed directly onto film, there is no need for color separation or multiple screens. This makes it perfect for highly customized orders and small batches with detailed artwork.

For bold, simple designs, screen printing is the better choice. Since each color needs a separate screen, designs with many colors increase both time and cost. This method works best for straightforward artwork with fewer colors.

• Cost Involved

When you compare the cost of DTF against screen printing, the former is usually more affordable for small custom designs because of lower setup costs. You don’t need a screen or a lengthy setup process. Thus, the method is best for one-off prints or on-demand orders. Moreover, DTF ink is usually less expensive than specialty inks that screen printing requires.

Screen printing is affordable for large production runs. But the cost for the initial setup for screen printing is high, as every color requires a separate screen. This makes the whole process affordable only when you are printing in large quantities.

• Fabric Choices

DTF is a versatile printing method that can be used on different fabric materials, including cotton, nylon, polyester, and more. This makes the method the best choice for printing on different textiles, including home goods and apparel. Moreover, it works well both in dark and light-colored fabrics. The printing method can be used to print on surfaces, such as leather, too.

Even though screen printing is effective, like polyester and cotton, it is not as versatile as DTF when it comes to printing on non-fabric materials. The process is suitable for flat surfaces. Moreover, the method works best on light-colored materials. So, without additional steps, it can be difficult to get vivid prints on dark fabrics.

• Number of Colors

DTF printing allows full-color designs with no limitations on the number of colors. Because it works directly from digital files, multi-colored and detailed designs can be printed without affecting setup time or cost. This makes DTF an excellent choice for artwork with a wide color range.

On the other hand, screen printing needs separate screens for every color. This makes the printing method time-consuming and expensive for designs that have multiple colors. Every color in the design will increase the cost and time. This makes screen printing a less affordable choice.

• Quantity

DTF printing is well-suited for small to medium print runs and on-demand custom projects. With minimal setup required, production can be scaled up or down without significant changes in time or cost. This flexibility makes it ideal for businesses handling a wide range of designs in smaller quantities.

Screen printing is most efficient for large production runs, as higher volumes reduce the cost per unit and make bulk orders more economical. However, the setup time and initial costs for each batch make it less suitable for smaller quantities.

• Upfront Investment

DTF printing requires a much lower upfront investment compared to screen printing. The main costs include the printer, inks, film, and a heat press. This makes DTF an excellent choice for startups or businesses that want to offer custom products without heavy initial expenses.

Screen printing needs more considerable upfront investment in equipment, including a drying system and multiple screens. The cost of buying and maintaining the equipment can be a lot for small businesses, especially if it requires a large production in bulk.

• Durability

In terms of durability, screen printing has an edge because of its thicker ink layers that can withstand frequent washing without fading. Designs that are printed using screen printing are known their longevity, particularly if they are applied to the fabric and cured well. Hence, screen printing is a preferred choice for items that require durability, such as sportswear or uniforms.

Although DTF is a newer technique and may not fully match the longevity of screen printing, its prints can still withstand regular washing. With the right inks and proper transfer process, DTF durability can be quite comparable.

• Production Speed

DTF printing is fast when it comes to the printing setup. As the design is printed digitally, it requires no screens or coating with emulsion. Thus, DTF printing method is best for urgent orders or quick turnarounds. However, as soon as the setup is complete, the printing speed is moderate.

Unlike DTF, Screen Printing has a slow setup process. For each color in the design, a separate mesh screen has to be prepared and registered. This can take a lot of time and is impractical for quick runs. But once the setup is complete, a high-volume screen press is fast and can print hundreds of garments every hour. This is a big advantage for large-scale production.

Which Printing Method is Better for Your Project?

DTF is a better option if you are printing garments in full color and want them to look vibrant on dark fabrics. It is an affordable choice for small runs. But if it is a large print run, you should choose screen printing.

Thus, if the printing project is more complicated and has multi-color designs, DTF is a better choice. For large quantity prints in a simpler design, screen printing is the best choice.

Both screen and DTF printing have clear advantages based on your priorities. Choosing the right printing technique can have an impact on the look and feel of the print.