Types of Printing on Shirts: A Complete Guide to Custom Apparel Techniques

In today’s fashion and merchandising world, custom t-shirts have become a staple—from branding and promotional campaigns to personal style and special events. One of the most important aspects of creating a custom shirt is choosing the right printing method. Different printing techniques offer varying results in terms of quality, texture, durability, cost, and suitability for design complexity or fabric type.

In this article, we’ll explore the most popular types of printing on shirts, their benefits, drawbacks, and when to use each one. Whether you're starting a t-shirt business or designing a one-off shirt for an event, understanding these printing methods will help you make the best choice.

1. Screen Printing

Screen printing, also known as silk screening, is one of the oldest and most widely used shirt printing methods. It involves creating a stencil (or screen) for each color in the design and using a squeegee to press ink through the screen onto the fabric.

Pros:

• Excellent for bulk orders

• Produces vibrant, long-lasting prints

• Great for bold and simple designs

Cons:

• Not ideal for designs with many colors or fine detail

• Setup costs are higher for small quantities

Best for: Promotional shirts, company logos, team uniforms, simple designs with limited colors.

2. Direct to Garment (DTG) Printing

DTG printing uses a specialized inkjet printer to apply water-based inks directly onto the fabric. It works like a paper printer—only for shirts—allowing for detailed, full-color designs without screens or transfers.

Pros:

• High-resolution prints with unlimited colors

• Ideal for small batches and one-off designs

• Soft feel, as the ink soaks into the fabric

Cons:

• Best on 100% cotton fabrics

• Slower process for large volumes

• Colors may fade slightly over time if not cared for properly

Best for: Photographic prints, detailed graphics, low-quantity custom orders.

3. Heat Transfer Printing

Heat transfer involves printing a design on special transfer paper and then using a heat press to transfer the image onto the shirt. There are multiple subtypes, such as vinyl heat transfers and digital heat transfers.

Pros:

• Versatile and easy to set up

• Good for small runs and on-demand printing

• Allows customization like names and numbers

Cons:

• May peel or crack after multiple washes

• Not as breathable as other methods

• Slightly stiff feel depending on the material

Best for: Sports jerseys, DIY t-shirts, personalized designs.

4. Sublimation Printing

Sublimation printing uses heat to transfer dye into polyester fabrics. The ink becomes a gas and embeds itself into the fibers, creating a vibrant, permanent print.

Pros:

• Ultra-durable and fade-resistant

• No peeling or cracking

• Soft feel—ink becomes part of the fabric

Cons:

• Only works on polyester or poly-blend fabrics

• Not suitable for cotton

• Best on white or light-colored shirts

Best for: Performance wear, all-over printed shirts, photo-realistic designs on polyester fabric.

5. Vinyl Printing (CAD-Cut)

This method uses a machine to cut designs out of colored vinyl sheets, which are then heat-pressed onto the shirt. Often used for lettering or small graphics.

Pros:

• Durable and bold prints

• Great for individual customization

• Ideal for text and simple designs

Cons:

• Limited in color and complexity

• Can feel heavy or rubbery on the shirt

Best for: Names and numbers on sportswear, simple logos, one-color graphics.

6. Discharge Printing

Discharge printing removes the shirt's dye color and replaces it with a new color using a special chemical process. This works only on darker 100% cotton shirts.

Pros:

• Soft, vintage-style prints

• Great for distressed or faded designs

Cons:

• Works best on 100% cotton

• Limited color options

• Involves chemicals and special handling

Best for: Retro-style prints, soft-hand designs on dark shirts.

7. Puff Printing

Puff printing is a type of screen printing that uses a special additive to create a raised, 3D effect on the design once it’s heated.

Pros:

• Unique texture and visual appeal

• Great for artistic and playful designs

Cons:

• Limited design compatibility

• Not ideal for fine detail

Best for: Fashion-forward designs, kidswear, artistic apparel.

Choosing the Right Printing Method

When deciding which shirt printing method to use, consider the following:

• Quantity: Screen printing is cost-effective for bulk orders, while DTG and heat transfer are better for small batches.

• Design Complexity: DTG and sublimation handle intricate, colorful designs best.

• Fabric Type: Cotton works best for DTG and screen printing, while sublimation requires polyester.

• Durability: Sublimation and vinyl offer strong resistance to wear and tear.

• Feel: For a soft, lightweight feel, opt for DTG or discharge printing.

Final Thoughts

Understanding the types of printing on shirts is crucial when designing or selling custom apparel. Each method has unique strengths and limitations that affect the final product’s look, feel, durability, and cost. Whether you're a small business owner, a designer, or a customer placing a custom order, choosing the right technique ensures you get a high-quality result that meets your expectations.

By selecting the right printing method for your needs, you’re not just creating a shirt—you’re delivering a design that lasts, wears well, and tells a story.