When choosing the right printing method for custom apparel, cost is one of the most important factors. Two of the most popular options today are DTF (Direct to Film) printing and screen printing. But which one is actually cheaper—and more profitable—for small to medium print businesses?
In this guide, we break down the true cost of DTF vs Screen Printing, including setup, materials, labor, and order size, so you can make the best decision for your business.
What Is DTF Printing?
DTF printing (Direct to Film) is a modern digital printing method where designs are printed onto a special transfer film, coated with hot-melt powder, cured, and then heat-pressed onto garments.
Key Advantages of DTF Printing:
- No screens required
- Ideal for short runs and custom orders
- Full-color prints with fine detail
- Works on cotton, polyester, blends, and dark fabrics
What Is Screen Printing?
Screen printing is a traditional printing method where ink is pushed through a mesh screen onto fabric. Each color in the design requires a separate screen.
Key Advantages of Screen Printing:
- Very low cost per shirt for bulk orders
- Long-lasting prints
- Excellent for simple, one- or two-color designs
DTF vs Screen Printing Cost Breakdown
1. Setup Costs
DTF Printing Setup Cost
- Minimal setup
- No screens or color separations
- Ideal for one-off or low-quantity orders
Estimated setup cost: Very low
Screen Printing Setup Cost
- Screen creation per color
- Emulsion, exposure, washing, and drying
- Time-consuming for small orders
Estimated setup cost: High
👉 Winner for low setup cost: DTF printing
2. Cost Per Shirt (Small Orders: 1–20 Pieces)
DTF Printing Cost Per Shirt
- Transfer film
- DTF ink
- Hot-melt powder
- Heat press time
Average cost per shirt: Medium but consistent
Screen Printing Cost Per Shirt
- High due to screen setup being spread over few items
Average cost per shirt: High
👉 Winner for small orders: DTF printing
3. Cost Per Shirt (Bulk Orders: 50–500+ Pieces)
DTF Printing
- Cost stays nearly the same per shirt
- Not ideal for very large runs
Screen Printing
- Setup cost spread across many shirts
- Extremely low per-unit cost
👉 Winner for bulk orders: Screen printing
4. Labor and Production Time
DTF Printing
- Faster turnaround
- Less skilled labor required
- Ideal for on-demand printing
Screen Printing
- More manual steps
- Skilled labor required
- Slower for short runs
👉 Winner for speed and flexibility: DTF printing
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