DTF vs Sublimation, DTG, Screen printing, White Laser Toner And Vinyl

About This Guide

This guide is brought to you by a printing company with nearly a decade of hands-on experience in the industry. What started as a small side hustle has grown into a state-of-the-art print shop. Over the years, we’ve gained extensive first-hand experience with all major printing methods and have witnessed the dramatic evolution of the custom apparel industry.

The digital textile printing market was valued at approximately $5.66 billion in 2024 and is projected to reach $6.35 billion in 2025, with digital methods like DTF and DTG driving much of this growth. The custom T-shirt printing industry alone is expected to reach $10 billion by 2025. This guide will help you understand which printing method is right for your business in this rapidly evolving landscape.

Quick Comparison at a Glance

Method	Entry Cost	Best For	Fabrics	Durability	Learning Curve
DTF	$1,500–$10,000	Small–Medium Business	All fabrics	Excellent	Low
DTG	$3,500–$20,000+	Premium Cotton	Cotton/blends	Very Good	Medium
Sublimation	$300–$2,000	All-over prints	Polyester only	Excellent	Low
Screen Print	$1,000–$5,000	Bulk orders 500+	Most fabrics	Excellent	High
Vinyl/HTV	$200–$1,000	Simple designs	Cotton/poly	Good	Low

DTF Printing (Direct-to-Film)

DTF printing has emerged as the dominant technology for small and medium-sized apparel businesses in 2024-2025. This innovative method prints designs onto a special PET film, applies adhesive powder, and then heat-transfers the image onto fabric. In 2024, over 60% of new custom apparel startups chose DTF over traditional methods for their initial production runs.

Pros

• Low barrier to entry: Entry-level printers start at $1,500–$3,000, with complete setups around $5,000–$10,000
• Universal fabric compatibility: Works on cotton, polyester, nylon, blends, leather, and even some hard goods
• No pretreatment required: Unlike DTG, you can print immediately without fabric preparation
• Excellent for dark garments: Vibrant white ink base ensures colors pop on any fabric color
• Transfers can be stored: Print in batches and apply on demand—ideal for inventory management
• Unlimited colors: Full CMYK printing with gradients and photorealistic capability
• Outstanding durability: Prints can withstand 35-50+ washes without significant fading

Cons

• Slight plasticky feel initially: Though this softens after a few washes
• Not as soft as DTG: The print sits on top of fabric rather than absorbing into fibers
• Daily maintenance needed: Requires printing regularly to prevent ink clogs
• Limited special effects: Cannot produce glitter, reflective, or metallic finishes like vinyl

DTG Printing (Direct-to-Garment)

DTG printing applies water-based ink directly onto fabric using modified inkjet technology. It’s been a staple in the industry for years and produces the softest prints with exceptional detail on cotton garments. However, the technology comes with significant drawbacks that have made DTF more attractive for most small businesses.

Pros

• Softest hand feel: Ink absorbs into fabric fibers, creating prints you can barely feel
• Exceptional detail: Up to 2,400 DPI resolution—ideal for photos and fine line art
• Eco-friendly inks: Water-based inks with low environmental impact
• Quick single-item production: Excellent for one-off custom pieces
• Direct printing: Prints directly onto garments—no film transfer step

Cons

• High entry cost: Quality machines start at $3,500+ with professional units costing $13,000–$250,000
• Pretreatment required: Dark garments need pretreatment solution—additional time and equipment
• White ink clogging: Notorious maintenance issues—printheads cost $1,000–$1,800+ to replace
• Limited fabric compatibility: Best on 100% cotton; struggles with polyester and synthetics
• Cannot sit idle: Leaving the printer unused for days risks expensive printhead damage
• Slower for high volume: Two-step curing process limits throughput

Sublimation Printing

Sublimation uses heat to convert special dyes from solid to gas, which then bonds permanently with polyester fibers. The result is incredibly durable, vibrant prints that won’t crack, peel, or fade. It’s ideal for sportswear, promotional products, and all-over print designs—but comes with strict material limitations.

Pros

• Very affordable entry: Can start with a converted inkjet printer for a few hundred pounds
• Minimal maintenance: Sublimation ink doesn’t clog easily like DTG white ink
• Exceptional durability: Prints become part of the fabric—they never crack, peel, or wash out
• No hand feel: The dye absorbs completely into fibers with zero texture
• Versatile product range: Works on mugs, keyrings, coasters, phone cases, and more with polymer coatings
• All-over print capability: Perfect for cut-and-sew production on large format printers

Cons

• Polyester only: Requires minimum 65% polyester content for acceptable results; 100% polyester for best results
• Light colours only: Cannot sublimate onto black or dark garments
• Cotton workarounds are complex: Coating sprays and sublimation HTV add cost, reduce softness, and require more skill
• No white ink: The fabric color shows through—designs rely on the base material

Screen Printing

Screen printing remains the industry standard for bulk orders, especially when producing hundreds or thousands of identical garments. Each color requires a separate mesh screen, making setup time-consuming but incredibly efficient once running. While DTF has captured much of the small-batch market, screen printing still dominates high-volume production.

Pros

• Unmatched efficiency at scale: Once set up, can produce hundreds of shirts per hour
• Lowest per-unit cost for bulk: Setup costs spread across volume make large orders very affordable
• Exceptional durability: Thick ink application withstands heavy use and repeated washing
• Special effects possible: Can achieve puff prints, metallic finishes, and specialty inks
• Wide color range: Pantone color matching for consistent brand reproduction

Cons

• Not viable for small orders: Setup fees of $50–$200 per design make one-offs and small runs unprofitable
• Steep learning curve: Mastering screen printing takes significant practice and skill
• Requires more space: Screens, exposure units, washout stations, and drying racks need room
• Messy process: Involves emulsions, chemicals, ink mixing, and extensive cleanup
• Limited color complexity: Each color needs a separate screen—full-color prints are expensive
• Slow design changes: New artwork requires creating entirely new screens

Vinyl / Heat Transfer Vinyl (HTV)

Heat transfer vinyl involves cutting designs from colored vinyl sheets and heat-pressing them onto garments. While DTF has replaced vinyl for many applications, HTV still shines for special effects and simple designs that benefit from metallic, glitter, or reflective finishes.

Pros

• Special effects library: Metal foil, reflective, glitter, holographic, flock, glow-in-the-dark—effects DTF cannot achieve
• Very low startup cost: A vinyl cutter and heat press can get you started for under $500
• Beginner-friendly: Simple process with machines like Cricut and Silhouette widely available
• Good for names and numbers: Perfect for sports jerseys and simple text-based designs
• Durable on simple designs: Well-applied vinyl can withstand 25-30+ washes

Cons

• Time-consuming weeding: Complex designs require tedious removal of excess vinyl
• Distinct vinyl feel: Creates a raised, plastic-like layer on the fabric
• Design limitations: Intricate details, gradients, and photorealistic images are not possible
• Peeling over time: Edges can lift after repeated washing, especially on complex cuts
• Layering challenges: Multi-color designs require stacking vinyl layers, creating bulk

The 2025 Verdict: Which Method Should You Choose?

For Small to Medium Businesses: DTF Wins

In 2025, DTF has firmly established itself as the smart choice for small and medium-sized apparel businesses. It offers the perfect balance of quality, versatility, and affordability that DTG promised but couldn’t deliver at accessible price points. With entry-level printers starting around $1,500 and complete professional setups available for $5,000–$10,000, DTF eliminates the financial barriers that made DTG impractical for starting businesses.

DTF allows you to print on 100% cotton, polyester, blends, and even challenging materials like nylon and leather—all without pretreatment. Your prints will have great feel and washability (35-50+ washes), and you can produce on-demand quickly without worrying about your printer sitting idle for a few days. The ability to pre-print transfers and store them for later application provides inventory flexibility that other methods simply cannot match.

When DTG Still Makes Sense

DTG remains the go-to when the absolute softest hand feel is paramount. For premium cotton products where customers are willing to pay extra for that “no print” feel, DTG delivers unmatched quality. If your business model centers on high-end cotton apparel with photorealistic detail, and you have the budget for proper equipment and maintenance, DTG can justify its higher costs.

When Screen Printing Dominates

For orders of 500+ identical garments with simple, limited-color designs, screen printing remains unbeatable on cost per unit. Once your screens are made, you can produce hundreds of shirts per hour at pennies per print. Many successful print shops use both DTF for custom and short runs while relying on screen printing for mass production contracts.

When to Use Sublimation

If your business focuses on polyester sportswear, promotional products (mugs, keyrings, etc.), or all-over print designs, sublimation offers the lowest cost and highest durability. The prints literally become part of the material and will never crack or peel. Just remember: you’re locked into polyester and light-colored products.

When Vinyl/HTV is the Right Choice

Vinyl remains essential for special effects—glitter, metallic, reflective, and holographic finishes that no other method can replicate. It’s also perfect for simple names, numbers, and text on sports jerseys. For hobbyists or very small operations doing occasional custom items, the low startup cost makes HTV an accessible entry point.

Final Thoughts: Building Your Printing Business

The printing industry has transformed dramatically in recent years. DTF technology has democratized high-quality garment printing, making it accessible to home-based businesses and startups that would have struggled with the capital requirements of DTG or the complexity of screen printing. Many successful print shops now operate with multiple technologies, choosing the right method for each job.

If you’re just starting out, DTF provides the perfect foundation. Save money, focus on developing your brand, make your customers happy with vibrant, durable prints on any material they want. As your business grows and you’re generating enough revenue to justify expansion, you can always add screen printing capabilities for bulk orders or invest in a premium DTG system for ultra-soft cotton prints.

The key is matching your printing technology to your business model. Understanding the strengths and limitations of each method will help you serve your customers better, maintain healthy profit margins, and build a sustainable printing operation for years to come.

Good luck with your printing journey!