DTF vs Screen Printing

DTF vs Screen Printing: Why Direct-to-Film is Transforming the Garment Printing Industry

Regarding custom apparel and garment decoration, two popular methods continue to dominate the conversation: Direct-to-Film (DTF) printing and screen printing. While screen printing has long been the industry standard for high-volume jobs, DTF has emerged as a versatile, cost-effective, and modern alternative, especially for businesses prioritizing flexibility, speed, and detailed designs. In this article, we’ll take a closer look at how DTF printing compares to traditional screen printing and why more businesses are making the shift toward DTF as their preferred method.

What is Direct-to-Film (DTF) Printing?

Direct-to-Film (DTF) printing is a heat-transfer-based method where designs are digitally printed onto a special PET film using water-based inks. After printing, an adhesive powder is applied to the wet ink and cured using a heat source. The film is then placed on the fabric and heat-pressed, permanently transferring the design. Unlike Direct-to-Garment (DTG), which requires printing directly onto fabric and pre-treating garments, DTF allows for transfers that can be stored, transported, and pressed onto a wide range of fabric types when needed.

What is Screen Printing?

Screen printing is a time-tested method of garment printing where ink is pushed through a mesh screen onto the fabric beneath. Each color in the design requires a separate screen, and the process involves precise setup and alignment. Screen printing is known for its vibrant colours, durability, and cost-effectiveness when producing large volumes of the same design. However, it requires a significant amount of preparation, materials, and equipment, making it less ideal for small runs or custom one-off pieces.

Key Differences: DTF vs. Screen Printing

DTF Printing T-shirt

1. Setup and Workflow

Screen printing involves a more complex and time-consuming setup process. Each colour requires a separate stencil and screen, which must be aligned perfectly. Setting up even a simple multi-colour design can take hours and require expensive equipment.

DTF printing, on the other hand, is entirely digital. There’s no need for screens or colour separations. Once a design is ready, it can be printed immediately onto film and transferred with minimal preparation. This streamlined workflow makes DTF especially appealing to small businesses or on-demand operations that need fast turnaround with minimal overhead.

2. Print Volume and Efficiency

Screen printing excels in high-volume production. When printing hundreds or thousands of shirts with the same design, the cost per item drops significantly once the setup is done. For this reason, large-scale merchandise producers and promotional product companies often choose screen printing for bulk orders.

DTF, while not as efficient for large-scale uniform designs, shines in short runs and custom jobs. Because it doesn’t require screen setups or cleanup, DTF allows print shops to fulfill small or individualized orders quickly and profitably.

3. Colour and Detail

DTF printers use CMYK + white inks, allowing for full-colour gradients, detailed photo-quality prints, and intricate designs, without the limitations of screen count or ink mixing. Fine lines, small text, and complex colour transitions are handled effortlessly in DTF.

In contrast, screen printing requires separate screens for each colour, making it less suitable for photo-realistic or highly detailed designs. While screen printing delivers vibrant, solid colours, its resolution and gradient capabilities are limited.

4. Fabric Compatibility

One of DTF’s biggest advantages is its fabric versatility. DTF transfers can be applied to cotton, polyester, blends, nylon, and even leather, without the need for different inks or complicated adjustments. This makes DTF ideal for modern fashion, sportswear, workwear, and accessories.

Screen printing typically requires different inks and additives depending on the material. For example, printing on polyester may require a special blocker base or ink formulation to prevent dye migration. This increases cost and complexity for printers handling diverse garment types.

5. Durability and Washability

Both DTF and screen printing offer good durability when properly applied. Screen printing has long been known for its long-lasting results and resistance to wear, especially on cotton garments.

However, DTF printing has shown excellent wash resistance, with proper curing and pressing techniques ensuring prints that last dozens of wash cycles without cracking or fading. In many cases, DTF rivals or even exceeds the washability of screen prints, especially on synthetic or stretchy fabrics where screen prints may crack.

6. Customization and On-Demand Printing

The rise of e-commerce and personalized products has fueled the need for on-demand garment printing, where customers can order custom designs in small quantities. Screen printing is not economically practical for this model due to high setup costs.

DTF is perfect for on-demand and print-on-demand (POD) services. Shops can print and store transfers ahead of time, or create one-off items quickly without waste or added labour. This makes DTF ideal for Etsy sellers, apparel startups, and promotional vendors offering personalized designs.

Why Choose DTF Over Screen Printing?

For many printers, DTF presents a more modern, adaptable, and cost-efficient option. Here are some of the top reasons to consider DTF:

  • Low barrier to entry – DTF requires fewer materials and less equipment than screen printing.
  • Fast production turnaround – Skip screen setups and jump straight to printing and pressing.
  • Broad design capabilities – Handle full-colour artwork, gradients, and detailed designs easily.
  • Fabric flexibility – One method for multiple materials.
  • Ideal for small orders – Cost-effective for short runs, one-offs, or personalized items.

While screen printing remains a strong contender for large-scale, single-design production, DTF is quickly becoming the go-to solution for businesses seeking flexibility, lower overhead, and high-quality results across a range of garment types.

Best Direct-to-Film Printer in 2024

VersaSTUDIO BY-20

Roland DG has released the latest and most innovative Direct-to-Film printer, the Roland VersaStudio BY-20. It’s a highly versatile desktop device ideal for a range of direct-to-film apparel applications, such as creating custom T-shirts, sportswear, tote bags, and more. With its compact design, it is even perfect for small businesses that have small production space.

Further reading: Introducing The Roland VersaSTUDIO BY-20 Desktop Direct-to-Film Printer

DTF printing represents a significant shift in the garment printing industry—bringing speed, efficiency, and versatility to a process once dominated by labor-intensive screen printing. As consumer demands for customization and quick turnaround grow, DTF is rising to meet those challenges. Whether you’re starting a new t-shirt business, expanding your print offerings, or looking to modernize your production, DTF printing offers a compelling alternative that’s both future-proof and profit-friendly.

Are you a business owner looking to elevate your apparel customization game? Consider investing in direct-to-garment printing machines. Contact us today to explore your options and take the first step toward enhancing your business with the latest in t-shirt printing technology. Let’s turn your creative vision into a colourful, wearable reality!