If you're running a small apparel brand or just starting a custom t-shirt business, chances are you're comparing different printing methods. One question many creators face is: Is DTF or screen printing better for small orders? While both methods have their strengths, Direct-to-Film (DTF) printing is quickly becoming the top choice for small-batch and on-demand apparel printing.
Let’s explore the real-world costs, quality differences, and practical benefits of each method, especially when you're working with small orders.
Understanding Screen Printing: Tried and True, But Pricey for Small Runs
Screen printing is the classic method most people think of when it comes to t-shirt printing. It involves pushing ink through mesh screens—one for each color in your design—onto fabric.
Pros of Screen Printing:
- Great for large orders
- Durable prints that last
- Cost-effective per piece only at high volumes
Cons for Small Orders:
- High setup costs per design
- Limited color options without added cost
- Not ideal for small batches or custom one-offs
- Slower production due to manual setup and drying
For a simple one-color design in large batches (say, 100 or more shirts), screen printing is hard to beat. But when it comes to low quantities, the cost and hassle add up fast.
What Is DTF Printing?
DTF (Direct-to-Film) is a modern digital printing method where your artwork is printed onto a special film, coated with adhesive powder, and heat-transferred onto garments using a heat press.
Benefits of DTF Printing for Small Orders:
- No setup fees
- Vibrant, full-color designs at no extra charge
- Works on cotton, polyester, blends, and more
- Ideal for print-on-demand and personalized apparel
- High-quality results with a soft feel
DTF gives small business owners, Etsy sellers, and apparel startups the power to print only what they need — no waste, no bulk inventory, and no expensive screen setups.
Cost Breakdown: Screen Printing vs. DTF for Small Runs
|
Feature |
Screen Printing |
DTF Printing |
|
Setup Time |
Hours (screens, alignment) |
Minutes (print & press) |
|
Setup Costs |
$25–$75 per color/design |
$0 |
|
Minimum Order |
Usually 24–48 pieces |
1 piece or more |
|
Color Limitations |
Yes – each color adds cost |
None – full color included |
|
Design Flexibility |
Low (fixed screens) |
High (easy changes) |
|
Turnaround Time |
Slower |
Faster |
|
Cost Per Shirt (10 pcs, 4-color) |
$10–$15 |
$5–$7 |
As the chart shows, DTF printing offers more flexibility and lower total costs for small orders. That’s a big deal for startups or anyone running a small clothing brand on a budget.
Why Small Businesses Love DTF Transfers
Whether you're printing hoodies, t-shirts, tote bags, or baby onesies, DTF printing scales with your needs. You can print a few test designs, create limited drops, or handle single custom requests without worrying about breaking even.
DTF is perfect for:
- Small-batch orders
- Personalized apparel
- Limited-edition product drops
- Events or one-time promotions
- Side hustles and pop-up brands
There’s no pressure to print in bulk, so you’re not tying up money in inventory that may not sell.
What About Print Quality?
Let’s be clear: both screen printing and DTF can produce amazing quality. But the difference lies in application.
- Screen printing still edges out for large areas of solid color.
- DTF printing shines in photorealistic images, gradients, fine details, and full-color designs.
DTF prints have a slightly different feel — soft and flexible but still durable. With proper care, DTF prints can last 40–50 washes or more without fading, peeling, or cracking.
When Screen Printing Makes Sense
If you’re printing 100+ shirts with the same one- or two-color design, screen printing might save you money per shirt. Many large-scale merch companies still use it for bulk orders of promotional tees and uniforms.
But for anything smaller, DTF is more efficient, cost-friendly, and flexible.
Final Thoughts: DTF Wins for Small Orders Every Time
If you’re building a brand from the ground up or selling made-to-order apparel, DTF printing is the smarter, more cost-effective choice for small runs. You save on setup costs, turnaround time, and have total freedom to experiment with color, fabric, and design.
Looking to Print DTF Transfers in the USA?
Partner with a trusted DTF transfer provider in the United States that offers:
- No minimum order quantity
- Custom gang sheet options
- Fast shipping and expert support
- High-definition color and long-lasting results
Get started today and print your next design with confidence — without the bulk or the big investment.
