Screen Printing vs Digital Printing for Custom Tees

Screen printing is a stencil-based ink-transfer method where mesh screens selectively allow ink onto fabric, producing thick, durable prints that stand up to repeated wash and wear. By layering each color through separate screens, this technique delivers brilliant solids for logos and branding applications in large batches. For example, a nonprofit ordering 200 event shirts benefits from screen printing’s low per-unit cost and long-lasting vibrancy.

Screen printing for custom tees involves four key steps:

1. A digital design is separated into individual color channels and burned onto mesh screens.
2. Ink is placed at the top of each screen and squeegeed through open mesh areas onto the garment beneath.
3. Each color layer is printed sequentially, creating crisp, vibrant imagery.
4. Finished shirts pass through a conveyor dryer to cure inks and lock in durability.

These steps ensure that printed tees resist cracking and fading, making screen printing ideal for bulk orders and branded uniforms.

• Outstanding durability that resists abrasion and frequent laundering
• Lower per-unit cost on large runs (100+ shirts) thanks to amortized setup fees
• Exceptional color opacity and consistency on dark and light fabrics
• Versatility across cotton, poly-cotton blends, and performance materials

By capitalizing on the strength of plastisol and water-based inks, businesses achieve long-term brand visibility on every garment.

• Higher initial setup cost for screens and art separations
• Limited design complexity—fine gradients and photo-realistic details are difficult to reproduce
• Minimum order quantities to justify the investment in screen preparation
• Longer turnaround when multiple color layers require precise alignment

Jones, A., “Printing Industry Trends,” (2023)

This citation provides context for the cost comparisons between screen printing and digital printing, as discussed in the article.

Reviewing detailed pricing at Arizona Screen Printer’s screen printing price page clarifies break-even points.

Screen-printed ink sits atop the fabric, creating a thicker hand feel that showcases texture. Digital prints integrate into fibers, offering a smooth, soft touch. While screen printing adapts to virtually all fabric types, DTG and DTF require cotton-rich garments for optimal ink adhesion and vivid results.

• Large-volume orders (100+ shirts) seeking low unit cost
• Simple logos or branding with up to 6 solid colors
• Long-term uniform and promotional apparel that withstand frequent wash
• High-contrast designs on dark or performance fabrics

Local brands rely on Arizona Screen Printer’s expertise and equipment to reduce lead times and shipping costs. A Phoenix brewery ordering 250 staff shirts saved 40% compared to out-of-state providers by choosing our streamlined screen printing process.

• Small orders (under 50 units) with mixed artwork
• Photo-quality images, full-color photographs, and intricate gradients
• Rapid prototyping and sample production
• Personalized names, numbers, or variable data on each shirt

• Confirm fabric composition: 100% cotton yields the best vibrancy
• Anticipate slightly higher per-unit cost on large runs
• Plan for reduced wash durability compared to plastisol prints
• Factor pretreatment and drying times into turnaround estimates

Simple logos and limited color palettes align with screen printing; photo-realistic or gradient-heavy art demands digital printing’s precision. Matching method to artwork complexity prevents overpaying or sacrificing quality.

Budget considerations include setup fees versus per-unit costs. Businesses with larger budgets for initial screens can achieve the lowest unit price on bulk screen orders, whereas modest budgets and flexible quantities benefit from digital printing’s minimal setup.

Screen printing is generally more durable, with plastisol inks resisting cracking and fading over hundreds of wash cycles. Digital prints bonded into fibers offer good longevity but can show wear sooner under heavy laundering.

Digital printing is cheaper on small orders (typically under 50 units) because it avoids screen setup fees. Screen printing becomes more cost-effective at higher volumes by amortizing those initial costs across many shirts.