For small orders — typically under 50 shirts — DTF printing is usually the better choice. Screen printing requires a separate screen for every colour, so setup costs make tiny runs expensive and slow. DTF printing has almost no setup cost, handles full colour and fine detail in one pass, and works on dark or light garments alike.
How screen printing works — and where it wins
Screen printing pushes ink through a mesh stencil (one screen per colour) directly onto the fabric. Once the screens are burned and the press is set up, each additional shirt is cheap to print — which is exactly why it dominates large runs. For an order of 200 identical single-colour tees, screen printing is hard to beat on per-unit cost.
The catch is the setup. Every colour in your design needs its own screen, its own setup time, and its own cleanup. For a full-colour logo on just 20 shirts, those fixed costs can push the per-shirt price far higher than the garment itself. Multi-colour designs also lose sharpness on fine gradients and photographic detail — screen printing prefers bold, simple artwork.
How DTF printing works — and where it wins
DTF (direct-to-film) printing prints your design onto a special film — including white ink, which is the key advantage over older digital methods — then bonds a hot-melt adhesive powder to it. The transfer is heat-pressed onto the garment at 300–320°F (150–160°C) for 10–15 seconds with firm, even pressure. The film is peeled away (cold or warm peel, depending on the film type), and the design is fused into the fabric.
Because there's no screen to burn, setup cost is effectively zero. One shirt costs almost the same per unit as twenty. The print handles unlimited colours, gradients, photos, and tiny text in a single press, and it works on cotton, polyester, blends, hoodies, and even hats — fabrics where vinyl and some screen inks struggle.
Cost comparison for small orders
Here is a realistic breakdown for 20 custom t-shirts with a full-colour front logo in Canada:
- Screen printing: setup/screen fees ($25–40 per colour × 4 colours), plus the per-shirt print fee. A four-colour design on 20 shirts often lands at $18–28 per shirt all-in, and shops may refuse the job entirely at that quantity.
- DTF printing: no screen fees; the cost is the transfer plus the garment. A comparable 20-shirt run typically lands at $12–16 per shirt, and the price stays proportional whether you order 5 or 50.
- The crossover point: somewhere around 50–100 shirts for simple 1–2 colour designs, screen printing starts winning. Below that — or with full-colour artwork at any quantity — DTF wins.
Durability and feel: are DTF prints any good?
A properly pressed DTF print is durable and machine-washable. It can feel slightly thicker than a soft-hand screen print on very large solid designs, but for chest logos, sleeve prints, and most everyday graphics the hand feel is light and flexible. To keep prints looking new, wash inside-out in cold water, hang dry or use low heat, skip the bleach, and wait 24 hours before the first wash.
Which should you pick? A quick decision guide
- Choose DTF if your order is under 50 shirts, your design has multiple colours, gradients, or photos, you need different names/numbers per shirt, or you want a fast turnaround with no minimum order.
- Choose screen printing if you're ordering 100+ identical shirts with a simple 1–3 colour design and want the lowest possible per-unit cost at scale.
- Running a small business or team? DTF lets you print exactly what you need — 20 staff tees today, 10 more next month — with identical quality every time, because there's no screen to store or remake.
FAQ
Does DTF work on dark shirts?
Yes — that's one of its biggest strengths. DTF prints a white ink base layer, so designs look vibrant on black, navy, and any dark garment without special prep.
Is there a minimum order for DTF printing?
No. Unlike screen printing, DTF has no screen setup, so there's no minimum — one shirt costs the same per unit as twenty.
Can I use my own artwork for DTF?
Yes. High-resolution PNG files with transparent backgrounds work best, and gradients, shadows, and tiny text all reproduce well.
How fast can I get DTF shirts printed?
Because there's no screen burning or colour setup, DTF turnaround is fast — often same-day or next-day for small runs. Amritu Customs prints in Langley, BC, so local orders skip cross-country shipping entirely.
Get small-batch custom tees without the screen-printing minimums
Ordering 20 shirts shouldn't mean paying setup fees for every colour. Amritu Customs prints in Langley, BC with fast turnaround and no minimums — full-colour DTF on cotton tees, hoodies, and more. Grab the $200 for 20 custom t-shirts deal for staff, teams, and events, or save money by nesting multiple designs on one custom DTF gangsheet and pressing them yourself. Looking for DTF printing near you in the Fraser Valley? That's us — send your artwork and we'll take it from there.