The Complete Guide to Screen Printing: Process, Science & 153 Expert Analysis

After reading more than 53 blogs online, we noticed that most of them explain screen printing in theory, and many do a great job at it.

But theory rarely answers the questions people actually care about, like:

1) Why does one print crack after 5 washes, while another lasts up to 50?

2) How can a small mistake in the screen printing process lead to reprints, refunds, and unhappy customers?

3) Why does the overall result change if the mesh count is off by 20–30 threads?

4) Why does 10% extra pressure cause bleeding or blurred edges?

So instead of writing another “screen printing explained” article, we decided to do something different.

In addition to our own experience screen printing more than a million products over the last 5 years and not receiving a single customer complaint, we also spoke with 153 screen printing experts across the US and Canada to validate our findings and add even more depth to this guide.

These are experts who have spent more than 10 years printing on everything from cotton t-shirts to polyester hoodies to stainless steel drinkware.

Experts who know exactly why one ink lasts and another fails.

Experts who have made every mistake you can imagine, learned from it, and continued to refine their skills.

And when we combined our experience with the insights of these experts, one thing became crystal clear: screen printing isn't a small or niche technique. It's one of the world's biggest and most widely used printing methods.

And the statistics prove that! :

1) The global screen printing market is already worth 8 billion dollars in 2025.

2) It is growing at more than 10 percent every year until 2030.

3) More than 1 billion t-shirts are screen-printed every year. 1 billion. Not a typo.

When an industry is this big, the small details start to matter a lot more than people think.

What we learned is this: screen printing is not just a technique. It is a series of small decisions that determine whether your print lasts 5 washes or 50.

Here are the decisions that matter most:

• Mesh count
• Emulsion thickness
• Cure temperature
• Squeegee angle

Each one of these choices affects how long your print survives in the real world.

This guide brings together everything we learned from those experts, along with practical explanations of the entire screen printing process, the science behind it, the 7 main print types, and screen printing comparisons with heat press, sublimation, DTG, and embroidery.

By the end, you will be able to look at any project and confidently choose the printing method that lasts the longest, looks the best, and makes the most sense for your brand.

Let's explore how screen printing actually works beyond the theory!

1. What Is Screen Printing?

Screen printing (also known as silk screening) is a printing technique where ink is pressed through a mesh stencil onto a substrate, usually fabric or hard goods, using a squeegee to create designs. It’s a widely used method for promotional products, branded merchandise, and corporate gifts.

Screen Printing Workflow:

1. Artwork Separation: Designs are separated by colour, and a separate stencil is created for each.
2. Screen Preparation: A mesh screen is coated with a light-sensitive emulsion.
3. Exposing the Stencil: The screen is exposed to light, creating areas where the ink can pass through.
4. Applying the Ink: Ink is pushed through the stencil using a squeegee to transfer the design onto the substrate.
5. Curing the Print: The print is heated to bond the ink and ensure durability.

2. How Does the Screen Printing Technique Work (Step-by-Step Process)

Screen printing might sound a bit technical, but it's actually quite simple once you understand the process. It's all about creating a stencil on a mesh screen and using that stencil to press ink onto a surface such as a t-shirt, tote bag, mug, or poster.

Here are six step-by-step explanations of how screen printing works.

Step 1: Design Creation

Every screen print starts with a design. The first step is to prepare the image you want to print. You can do this by drawing it by hand or creating it digitally, then printing it from a computer onto a transparent acetate film, which will be used to create the screen. Make sure the image is in black for best results.

(Credit: Metmuseum.org)

Why this step is important: Preparing clean, high-contrast artwork ensures sharper and more accurate prints.

Step 2. Screen Preparation

A screen is made from a piece of mesh stretched tightly over a frame. The mesh was once made of silk, but today it’s usually made from nylon or polyester.

The mesh count, or number of threads per inch, depends on the level of detail in the design:

• Higher mesh count: Best for fine lines and intricate details.
• Lower mesh count: Allows more ink flow and works well for bold designs.
  

Why this step is important: The mesh and emulsion coating determine how clean and detailed the final print will be.

Step 3: Exposing the Emulsion

Photo emulsion is a liquid that reacts to UV light and hardens when exposed. Screen printing makes use of this property to create the stencil. The emulsion is applied evenly to both sides of the mesh using a scoop coater or squeegee. The coating should be thin and uniform, with no gaps or missed spots. This step should be done away from UV light, ideally in a dimly lit or dark room, to prevent premature hardening.

Why this step is important: A smooth, evenly exposed emulsion layer is what creates a clean, accurate stencil. If this step is rushed or uneven, the final print can look patchy, fuzzy, or lose fine details.

Step 4: Creation of the Stencil

When the emulsion on the flat side of the screen is dry, place the transparency with your design upside down on the screen. Then, place a piece of glass on top to keep the transparency flat and in place. Now the screen is ready to be exposed. You can use sunlight by taking it outside, or use lamps as your light source. When exposed to light, a reaction occurs where the areas that receive light harden and will not wash away, while the unexposed areas stay soft. Rinse the screen gently with water to remove the soft emulsion. Once it’s clean, you’ve successfully transferred your design onto the screen.

(Credit: Metmuseum.org)

Why this step is important: This step transforms your artwork into a perfect stencil. If the exposure or washout isn’t done properly, some fine details in the design may be lost, or unwanted gaps may appear in the print.

Step 5: Printing the Design

The fabric to be printed on is laid flat on the printing table, and the screen is carefully placed on top of it. A thick layer of ink in the desired colour is applied to the top of the screen, and using a squeegee, the ink is spread across the screen to cover the stencil. The ink is pressed through the open areas of the stencil and transferred onto the fabric underneath, leaving the design. Only one colour is printed at a time, so multiple screens are used for multi-coloured designs.

(Credit: Metmuseum.org)

Step 6: Cleaning the Screen

Once the job is done, the screen is washed and the emulsion is removed so it can be used again for another design. Cleaning and reusing screens not only saves time but also cuts down on waste.

(Credit: Metmuseum.org)

Why this step is important: Cleaning extends the life of the screen and reduces waste, making the process more sustainable.

3. Why is Screen Printing a Popular Printing Method?

Screen printing is a popular printing method known for its durability and vibrant colours. It's especially preferred for branded merchandise (t-shirts, hoodies, jackets, hats, sweatshirts, tote bags, backpacks) and promotional products (mugs, bottles, glasses, coasters, pens, lanyards, keychains, umbrellas, drinkware, stickers) due to its ability to produce bold, long-lasting prints, especially on darker fabrics.

Here are 5 key reasons why screen printing is so popular:

1. Great Colour Range

Screen printing can produce intense, vivid colours that stand out on fabrics, including darker materials.
Why it's important: Studies show that 85% of consumers say that color is a key factor in making a brand memorable, and screen printing does exactly that, it makes your design stand out and be remembered.

2. Efficiency for Bulk Orders

Once the stencil (screen) is created, it can be used for multiple products, making it ideal for bulk orders.
Why this is important: With screen printing, you can reduce the cost per unit by up to 50% when ordering large quantities, making it a great option for businesses with bulk printing needs.

3. Durability

The ink used in screen printing bonds well with fabrics, giving long-lasting results even after repeated washings. Why it matters: Research shows that 60% of consumers value the durability of printed products, especially promotional items, as they need to last long enough to be seen multiple times.

4. Cost-Effective for Large Runs

Although it requires an initial setup for each design, the cost per item decreases with larger orders.
Why it's important: For orders of more than 100 items, screen printing can reduce per-unit costs by up to 30%, making it ideal for businesses looking to efficiently produce large quantities.

5. Limitations

Although screen printing is great for simple designs, the process requires separate screens for each colour, so complex, multicoloured designs can be more expensive and time-consuming.
Why it's important: For designs with more than 4 colours, you may face higher costs, as each colour requires a separate screen. This is why 47% of businesses prefer to simplify their designs to keep production costs low.

4. Scientific Aspects of Screen Printing

Screen printing isn’t just an art; it’s a science. Understanding how it works helps you choose the right method for your branded products, ensuring your designs are both cost-effective and durable.

Below, we analyze the scientific side of screen printing, including key components like silk screens, inks, and squeegees, as well as the important variables and common problems that screen printing engineers solve.

1. Key Components (Silk Screen, Ink, Squeegee)

For high-quality printing, screen printers need the right equipment. Let's take a look at the essential components: silk screen, ink, and squeegee, and see how each contributes to the printing process.

a. Silk Screen

The silk screen is the foundation of the screen printing process. It’s a mesh that holds your design and controls the ink flow as it passes through.

• Material: Usually made of polyester (formerly silk), offering durability and cost-effectiveness.
• Design Transfer: The screen is coated with emulsion and exposed to light to create a stencil for the design.
• Reusable: After printing, the screen can be cleaned and reused for future designs.

b. Inks Used in Screen Printing

Choosing the right ink for screen printing has a significant impact on the look, feel, and durability of your printed product.

In this section, we’ll explain how inks work, the most common types used, and how they vary in terms of durability, cost, and fabric compatibility.

How Ink Works

• The ink is forced through the mesh of the screen onto the fabric, then cured (heated) so it bonds properly.
• Key variables include ink type, ink deposit (thickness), curing temperature/time, and how well it works with the fabric.

Two Main Ink Types

Ink Type	Description	Durability (Approx.)	Best For
Plastisol Ink	Thick, opaque ink that sits on top of fabric, great for bold prints on dark garments.	30–50 washes when properly cured	Large orders, dark fabrics, bold designs
Water-Based Ink	Ink that soaks into fabric, gives a softer feel; more eco‑friendly option.	25–35 washes typical	Light fabrics, eco‑friendly projects, smaller runs

Practical Tips When Choosing Print Ink

• Confirm the fabric colour: Dark fabrics → requires opaque ink like plastisol (or white underbase + water‑based). Light fabrics → water‑based is a strong choice.
• Ask for wash tests: How many washes does the sample pass? What's the cracking/fading profile?
• Ask how the printer plans to cure the ink: Are they using proper temperature and time? Under‑curing leads to early wear/fade.
• If you need metallics, neon, puff effects, these are more easily achieved with plastisol ink.
• If sustainability is a priority, look for water‑based inks certified for low‑VOC or eco standards.

c. The Squeegee: Essential Tool in Screen Printing

A squeegee is a rubber blade held in a handle that’s used to push ink through the screen mesh onto the printing surface, such as fabric, paper, or plastic. The squeegee’s edge presses the ink into the fabric, while the rubber blade controls the amount of ink transferred, ensuring clean and crisp designs.

Key Elements of a Squeegee

Blade Material:

• Rubber: Common, flexible, and durable for general use.
• Polyurethane: More durable, used for tough inks or high-volume runs.

Blade Hardness (Durometer):

• Soft (Shore 50-60): Best for fine details and soft-hand inks.
• Hard (Shore 70-80): Ideal for bold designs and thicker inks.
  

Width and Shape:

• Width: Typically 12–36 inches; larger widths for bigger designs.
• Shape: Flat edge for general use, radiused edge for smoother flow.

Squeegee Tips for Screen Printing

• Choose the Right Durometer: Use a softer squeegee for detailed prints, harder squeegee for bold designs.
• Maintain Pressure: Keep consistent pressure for even prints.
• Angle: Use a 45-degree angle for optimal ink flow.
• Clean Regularly: Clean the squeegee to avoid ink build-up.

2. Screen Printing Key Factors

Factor	Description	Typical Range/Value
Mesh Count	The number of threads in the screen that affects print detail.	110 to 230 threads per inch
Ink Type	The type of ink used in the printing process.	Plastisol or Water-based
Ink Usage	The amount of ink needed for each print.	0.5 to 1.0 grams per square inch
Curing Time	Time needed to set the ink onto the fabric.	90 to 120 seconds at 320°F (Plastisol)
Durability (Wash Cycles)	How many washes the print can withstand.	30 to 50 washes (Plastisol)
Print Feel (Hand Feel)	How the printed area feels when you touch it.	Thicker (Plastisol) or Softer (Water-based)
Fabric Compatibility	What materials work best for screen printing.	Cotton, Polyester Blends, Fleece

3. 10 Common Screen Printing Problems and Their Solutions

1. Problem: Bubbling: Air Bubbles on Solid Prints
Cause: Rushing the print process, overloading the screen with ink, or using ink that’s too thick.
Solution:

• Slow down the squeegee motion.
• Use a firmer squeegee blade.
• Thin the ink with a specialized additive.
• Let the ink settle before printing.

2. Problem: Contamination - Unwanted Spots on Prints
Cause: Dust, lint, or oils on the screen or printing surface.
Solution:

• Clean the screen and workspace regularly.
• Handle fabric carefully to avoid transferring oils.
• Clean the fabric before printing to remove contaminants.

3. Problem: Ink Spreading - Blurry Edges
Cause: Runny ink, too much pressure from the flood coat, or a worn squeegee.
Solution:

• Add a hardener to the ink for better consistency.
• Adjust the flood bar to avoid contact with the screen.
• Replace or sharpen the squeegee for precise ink application.

4. Problem: Ink Leakage Around the Image
Cause: Foreign material under the stencil or ink that’s too thin.
Solution:

• Clean the underside of the screen.
• Use a thicker ink or add a hardener to prevent leakage.

5. Problem: Blur and Ghosting Effects
Cause: Too small of a gap between the screen and fabric, or uneven fixture height.
Solution:

• Set the off-contact distance to about the thickness of a nickel.
• Ensure the fixture and fabric are aligned evenly.
• Slow down the print speed to improve consistency.

6. Problem: Blurred and Distorted Images
Cause: Static electricity or excessive printing speed.
Solution:

• Increase snap-off distance and use an anti-static agent.
• Slow down the printing speed to reduce distortion.
• Lower mixing speeds to avoid bubbles in the ink.

7. Problem: Streaks in the Print
Cause: Damaged squeegee blade, imperfections on the flood bar, or nicks on the press bed.
Solution:

• Replace or sharpen the squeegee.
• Fix imperfections on the flood bar.
• Ensure smooth press beds to avoid uneven ink flow.

8. Problem: Mottling - Uneven Ink Absorption
Cause: Poor fabric quality or insufficient ink thickness.
Solution:

• Use a higher-quality stock.
• Increase ink thickness by using a coarser mesh.
• Use a more pigmented ink for better coverage.

9. Problem: Ink Drying in the Screen
Cause: High ink viscosity or elevated ambient temperatures.
Solution:

• Clean the stencil regularly and adjust ink viscosity with solvent.
• Use a retarder if the temperature is too high.
• Opt for a sharper squeegee to maintain consistent ink flow.

10. Problem: Incomplete Ink Coverage in Multicolor Prints
Cause: Silicone in the first ink layer, thick second ink, or solvent interference.
Solution:

• Change the ink formulation to reduce silicone content.
• Thin the second color ink for better coverage.
• Ensure the first ink layer is fully dry before applying the second.

5. 7 Main Types Of Screen Printing Process

1. Spot Colour Screen Printing

• What it is: Uses solid ink colors (Pantone-matched) applied to specific areas of a design.
• Best for: Designs requiring solid colors and clear edges.
• Pros: Ideal for simple logos with few colors.
• Watch-outs: Not suitable for designs with complex gradients or photographic artwork.
• Typical Use: Corporate logo apparel, branded merchandise.
  
  

2. CMYK Screen Printing

(Credit: 1Ink)

• What it is: A 4-color process using cyan, magenta, yellow, and black inks to create a full-color image.
• Best for: Photorealistic designs with many colors.
• Pros: Can print detailed designs with accurate colors.
• Watch-outs: Requires precise calibration for color accuracy.
• Typical Use: Complex art, full-color promotional items.

3. Simulated Process Screen Printing

(Credit: rushordertees)

• What it is: A method for printing full-color designs, often used for dark garments where standard CMYK can’t deliver vibrant colors.
• Best for: Dark apparel, photo-like images.
• Pros: High-quality print on dark fabrics, with greater detail.
• Watch-outs: More expensive due to multiple layers of ink.
• Typical Use: Full-color designs on black or dark shirts.
  

4. Halftone Screen Printing

(Credit: Catspitproductionsllc)

• What it is: Breaks down a full-color image into small dots to simulate gradients and shading.
• Best for: Designs requiring shading and gradients.
• Pros: Can replicate complex color nuances.
• Watch-outs: Not ideal for simple or solid-color designs.
• Typical Use: Detailed illustrations, multi-shaded artwork.
  

5. Water-Based Ink Printing

(Credit: rushordertees)

• What it is: Uses water-based inks that are absorbed by the fabric for a softer feel.
• Best for: Eco-conscious designs, light-colored fabrics.
• Pros: Soft feel, eco-friendly, and breathable.
• Watch-outs: Needs precise curing; not suitable for dark fabrics.
• Typical Use: Eco-friendly apparel, fashion-forward designs.
  

6. Plastisol Ink Printing

(Credit: rushordertees)

• What it is: The most common ink used in screen printing, creating vibrant, thick prints.
• Best for: Bold, durable prints on cotton and blends.
• Pros: Vibrant colors, highly durable.
• Watch-outs: Less eco-friendly, thicker feel on fabric.
• Typical Use: Promotional t-shirts, branded workwear.
  

7. Discharge Printing

• What it is: Removes the fabric color and replaces it with a new ink, ideal for soft prints.
• Best for: Soft, vintage-style prints on light-colored fabrics.
• Pros: Soft feel, great for retro designs.
• Watch-outs: Limited to light fabrics, more expensive.
• Typical Use: Soft-feel, vintage designs on t-shirts.

6. Screen Printing vs Other Printing Methods: (Heat Press, Sublimation, Embroidery and DTG)

When it comes to custom printing, screen printing is often the best approach, but it’s not the only option. There are several other printing methods, such as heat press, DTF, digital printing, sublimation, and more, that might be better suited to your goals. Each method has its own strengths, including speed, cost, design flexibility, and durability.

Let's take a look at how screen printing compares to these other methods so you can choose the best option for your next project.

1. Screen Printing vs Heat Press

When choosing a printing method for your corporate apparel or promotional products, the decision between screen printing and heat press can significantly impact your budget, timeline, and the quality of the final product. Both methods have their advantages, but understanding their strengths and limitations will help you select the best option for your needs.

Refer to the table below for a quick comparison of both methods.

Factor	Screen Printing	Heat Press
Best for Order Sizes	100+ units (bulk production)	1–50 units (small runs)
Colour Complexity	1–3 colours (max)	Full colour (up to 8 colours, including gradients)
Gradients and Photos	Limited (solid colours, not ideal for fine gradients)	Ideal (full-colour photos and gradients)
Fabrics and Materials	Cotton, polyester blends, canvas, nylon	Cotton, polyester, blends, performance fabrics
Durability After Washes	30+ washes (long-lasting prints)	10–20 washes (may fade or crack)
Hand Feel	Soft (especially with water-based inks)	Thicker, especially with vinyl (HTV)
Setup Time	2–3 hours for setup (depends on design complexity)	30 minutes to 1 hour (quick setup for small orders)
Cost Efficiency (Unit Cost)	CAD 5–12 per unit (for 100+ items, 1 colour)	CAD 8–20 per unit (for 24–50 items, full colour)
Turnaround Time	5–7 days (depending on complexity)	1–3 days (especially for small, quick orders)
Personalization	Challenging for small runs (1–10 items)	Easy and fast (names/numbers, 1–50 units)
Sustainability	Eco-friendly options (water-based inks, low chemical usage)	Less sustainable (vinyl, PVC)

Decision Guide: Screen Printing vs Heat Press

When choosing between screen printing and heat press for your corporate apparel and promotional products, consider the following factors to determine the best option for your needs. Each method has its own unique advantages, and the right choice will depend on your order size, design complexity, materials, and timeline.

Below is a simple 5-step outline to guide you through the decision-making process:

Step 1: Order Size and Reorder Frequency

Choose Screen Printing When:

• You need to print 100+ units.
• You are looking for the lowest cost per unit for large orders.
• You need consistent prints on larger runs.

Choose Heat Press When:

• You’re dealing with small orders (1–50 units) or on-demand projects.
• You need to personalize each item (e.g., names/numbers).
• Quick, low-volume runs are your priority.

Step 2: Design Complexity

Choose Screen Printing When:

• You have simple, bold designs (such as logos or text) with one to three colours.
• You need Pantone matching for precise brand colours.
• Your design doesn’t have fine gradients or complex details.
  

Choose Heat Press When:

• Your design includes full-colour artwork, photos, or complex gradients.
• You need to print intricate designs or multiple colours quickly.
• You want to print full-colour on smaller items like mugs or coasters.
  

Step 3: Material and Product Type

Choose Screen Printing When:

• You’re working with cotton or cotton blends (such as t-shirts, hoodies, tote bags).
• You need to print on dark fabrics for bold solid colours.
• You’re printing on highly textured items that require long-lasting prints.
  

Choose Heat Press When:

• You are working with polyester fabrics (especially for sportswear or performance wear).
• You need to print on hard goods (e.g., mugs, coasters, phone cases).
• Your items are light-coloured polyester (perfect for sublimation).
  

Step 4: Durability and Washability

Choose Screen Printing When:

• You need high durability for frequent washing (e.g., work uniforms, company t-shirts).
• The design needs to withstand wear and tear for long-term use.
  

Choose Heat Press When:

• You’re working with shorter-term promotional items (e.g., event t-shirts).
• You need a soft, flexible print on performance wear or specialty items.
• Durability isn’t a major concern for your use case.

Step 5: Turnaround Time

Choose Screen Printing When:

• You have more time (usually 5–10 business days) for setup and production.
• Your order is large and you’re willing to wait a bit longer for efficient production at scale.

Choose Heat Press When:

• You need fast turnaround (ideal for 1–3 days).
• The order is small and can be processed quickly.
  

Real-World Scenarios: Screen Printing vs Heat Press

Choosing the right printing method for your corporate apparel or promotional products can make your project a success or a failure. Screen printing and heat presses (including digitally printed transfers) are two of the most popular options, and both have their own strengths. Whether you're working with bulk orders or individual items, simple designs or complex artwork, it's important to know when to use each method.

Below, we break it down with real-world scenarios to help you choose the option that best suits your needs.

Real-World Scenarios: Screen Printing vs Heat Press

Scenario	Best Method	Why
Scenario A: 500 Cotton Tees, 1-Colour Logo for a Conference in 3 Weeks	Screen Printing	Large order, simple design. Screen printing is cost-efficient and delivers bold, durable prints.
Scenario B: 24 Polyester Jerseys with Names/Numbers, 4 Days	Heat Press (digitally printed transfers/HTV)	Small order with personalization; heat press is faster and ideal for names/numbers.
Scenario C: 75 Tote Bags, 2-Spot Colours, Brand Pantones	Screen Printing	Multiple colours on a larger run; screen printing offers cost efficiency and vibrant colours.
Scenario D: 30 Hoodies with Full-Colour Gradient Art, 1 Week	Digital Transfers (Heat Press)	Heat press is ideal for full-colour gradients and offers a quick turnaround.

2. Screen Printing vs Sublimation

When choosing between screen printing and sublimation for your branded merchandise, promotional products, or corporate gifts, we recommend screen printing for bulk orders and simpler spot-colour designs, and sublimation when you need full-colour artwork, polyester materials, or seamless all-over prints. The main exception: if your products are dark cottons and you need vibrant solid colours, screen printing is the better choice.

See the table below for a quick comparison of both methods.

Factor	Screen Printing	Sublimation
Best for Materials	Cotton, cotton-blends, dark fabrics, hard goods (special inks)	Light-coloured polyester, polymer-coated hard goods (mugs, mouse pads)
Product Types	T-shirts, hoodies, totes, jackets, caps, drinkware (printable surface)	Performance apparel (poly), mugs, bottles, mouse pads, ceramic mugs
Order Size / MOQ	100+ units typical; cost-effective in bulk	Small to medium runs (10-500 units) viable, especially full-colour
Setup Cost Drivers	Screens per colour, under-base for darks, manual registration	Transfer paper, polymer coating, heat press time
Per-Unit Cost (Canada, estimate)	CAD 5-12 for 1-colour screen print at 100+ units (industry estimate)	CAD 8-20 for small full-colour sublimation runs (source: industry range)
Lead Time	5-10 business days (Canadian fulfilment)	2-7 business days (on-demand friendly)
Durability / Wash Cycles	Excellent; may fade, crack or peel after 50-100 washes depending on ink & care	Excellent; because ink is embedded, no peeling or cracking in 100+ washes
Colour Coverage	Spot colours (typically 1-4); gradients/photos cost more	Full-colour (CMYK) plus gradients/photos
Print Feel / Hand	Slight raised ink feel (especially plastisol); specialty inks available	No extra feel, ink becomes part of fabric
Print Area Limits	Large area possible but multiple screens increase cost	Edge-to-edge/all-over print possible on suitable substrates
Pantone / Brand Colour Match	Excellent for Pantone/spot colours	Good, though limited by process colours and substrate consistency
Artwork Complexity	Best for simple logos, text, spot-colours	Best for complex art, full-colour photography, gradients
Environmental Notes	Plastisol inks may contain PVC; water-based inks are more eco-friendly	Lower waste and water use; substrate limited to polyester/polymer-coated
Typical Corporate Use Cases	Bulk branded apparel, dark cotton tees, simple logos	Photo-quality merchandise, performance wear, light poly totes
Common Pitfalls	High setup cost for small runs; bleed on dark fabrics	Limited to polyester/light fabrics; higher blank cost; cannot print white ink on dark fabric

Decision Guide (Screen Printing vs Sublimation)

Here are the key factors we evaluate before recommending a method at GiftAFeeling:

Criteria & Trade-Offs

• Quantity & cost per unit: Bulk orders favour screen printing, small custom runs favour sublimation.
• Design style: Simple logos → screen printing; full-colour photos or gradients → sublimation.
• Material & blank type: Cotton/dark fabrics → screen printing; polyester/light fabrics or hard goods → sublimation.
• Durability & branding: If wash-fast longevity and brand conformity matter, screen printing often wins; for embedded prints and comfort, sublimation excels.
• Timeline & variation: Tight deadlines or varied designs favour sublimation; long-lead bulk runs favour screen printing.
• Sustainability/brand ethics: Water-based screen inks or on-demand sublimation help meet eco goals but each has substrate constraints.
  

Choose Screen Printing When:

• You’re ordering hundreds of cotton or cotton-blend tees with a 1–3 colour logo for a corporate event.
• Your fabric is dark and you need vivid spot colours.
• You require exact brand-colour matching (Pantone) and no photo gradients.
• You’re producing branded apparel for employee uniforms with minimal design variation.
• You need specialty inks or texture effects (metallic, puff) that sublimation cannot do.
  

Choose Sublimation When:

• You’re printing performance sportswear in light-coloured polyester for a team, with full-colour gradients and photos.
• You’re producing custom mugs, bottles, mouse-pads or other hard goods with full-colour artwork.
• You need low minimums and fast turnaround for a promotional campaign.
• You want a “no-feel” print that embeds into the fabric for comfort and durability.

Sustainability matters, and you prefer on-demand printing with minimal waste.

Real-World Scenarios: Screen Printing vs Sublimation

When it comes to choosing between screen printing and sublimation, real-world scenarios can help clarify which method is best suited for specific needs. Below are some practical examples of different print projects, showing which method is most effective depending on the product, order size, timeline, and design.

Real-World Scenarios: Screen Printing vs Sublimation

Scenario	Best Method	Why
Scenario A: 500 Cotton Tees, 1-Colour Logo for a Conference in 3 Weeks	Screen Printing	Large order, simple design. Screen printing is cost-effective and ideal for bold, durable prints on cotton.
Scenario B: 24 Polyester T-shirts with Full-Colour Logo, 4 Days	Sublimation	Full-colour design on polyester. Sublimation is best for vibrant colours and quick turnaround.
Scenario C: 75 Tote Bags with 2-Spot Colours, Pantone Match	Screen Printing	Pantone matching and spot colours work best with screen printing for accurate, bold prints.
Scenario D: 30 Hoodies with Full-Colour Artwork, 1 Week	Sublimation	Full-colour design on polyester. Sublimation is ideal for photo-quality prints and quick processing.

3. Screen printing vs Embroidery

When deciding between screen printing and embroidery for your branded merchandise, promotional products, or corporate gifts, consider your order size, design complexity, and fabric type. Screen printing is ideal for large orders, bold designs, and fabrics like cotton. On the other hand, embroidery excels for high-end looks, detailed logos, and durable finishes on items like hats and polos.

See the table below for a quick comparison of both methods.

Factor	Screen Printing	Embroidery
Order‑Size Break‑Even	Ideal for large runs (100+ units) where setup cost is spread over many items.	More cost‑effective at smaller quantities (10–50 units) for premium pieces.
Unit Cost – Low vs High Qty	Low volume: high per‑unit cost due to setup. High volume: CA ≈ $5–12 for 100+ units (1‑colour) (Canada estimate)	Setup via digitizing + stitch count; e.g., smaller runs: CAD ≈ $7–15 per item
Colour/Design Complexity	Best for spot colours and bold graphics; gradients/photo realism are harder.	Excellent for simple logos and text; less suited for large full‑colour coverage or photo effects
Fine Detail & Text	Good for fine lines and low‑text prints, but may crack over time if ink layers are thin.	Thread‑based detail is durable but very small text (< ¼″) may blur.
Fabric Compatibility	Works well on cotton, blends; dark fabrics require under‑base white.	Works best on woven heavier fabrics, polo knits, caps; less ideal on ultra‑light or stretchy knits.
Durability / Wash Cycles	Good if cured correctly; may fade/crack after 30‑50 washes under heavy use.	High durability: stitching becomes part of fabric, 100+ washes common.
Finish / Hand‑Feel	Flat ink on fabric, relatively lightweight, smooth.	Raised thread texture gives premium feel and high‑perceived value.
Brand / Colour Matching	Excellent for precise brand colours (Pantone matching) with spot‑colour inks.	Limited by thread colours; achieving exact Pantone match may be harder/expensive.
Turnaround / Setup Time	Setup (screens, separations) takes more time; large runs then print quickly.	Digitizing and stitch set‑up add time; per‑item production slower.
Sustainability / Waste	Inks may include PVC/plastisol; water‑based options better. Screens create waste.	Thread and backing generate waste; no inks = less chemical input.

Decision Guide (Screen Printing vs Embroidery)

Choosing between screen printing and embroidery depends on factors such as order size, design complexity, and the type of product being branded. Both methods have distinct advantages, but understanding when to use each is key to achieving the best results for your corporate gifts or promotional products.

Below is a simple 5-step outline to guide you through the decision-making process:

Step 1: Order Size and Volume

Choose Screen Printing When:

• You need to print 100+ units.
• You want cost savings on bulk orders.
• Your design uses spot colours and bold graphics.

Choose Embroidery When:

• You are working with small to medium runs (10–50 units).
• You need a premium, textured finish for high-end items like polos and hats.
• The design is simple (e.g., logo, text).

Step 2: Design Complexity

Choose Screen Printing When:

• Your design is simple, like logos or text.
• You need Pantone matching for brand consistency.
• Your design requires bold colours or large coverage (e.g., full front prints).

Choose Embroidery When:

• You have a simple logo or text-heavy design.
• You want a premium, tactile feel for high-end garments.
• Fine details are essential (though keep text size manageable).

Step 3: Material and Product Type

Choose Screen Printing When:

• You're printing on cotton or polyester blends.
• Your product is dark or heavier fabrics like t-shirts, hoodies, or tote bags.
• You need large area prints that cover the fabric.

Choose Embroidery When:

• Your product is woven or polyester.
• You need to brand premium products like polos, caps, or outerwear.
• You need a textured finish that stands out.

Step 4: Durability and Care

Choose Screen Printing When:

• You need bold, durable prints for long-term branding.
• Your items will face frequent washing (e.g., workwear, event merchandise).
• Choose Embroidery When:
• You want high durability with no fading or cracking.
• The product will face heavy wear and tear (e.g., work uniforms, hats).

Step 5: Budget and Cost

Choose Screen Printing When:

• You're working with larger budgets for bulk orders (100+ items).
• You need the most cost-effective option for simple designs.
  

Choose Embroidery When:

• You have a smaller budget for smaller, premium runs (under 50 items).
• You want to add premium finishes without excessive setup fees.

Real-World Scenarios: Screen Printing vs Embroidery

Choosing the right printing method for your branded merchandise, corporate gear, or promotional products depends on the specifics. Whether you need bulk printing, fine detail, or a premium look, each method has its strengths. In these real-world scenarios, we’ll help you decide when to choose screen printing or embroidery, based on order size, design, and product type.

Real-World Scenarios: Screen Printing vs Embroidery

Scenario	Best Method	Why
Scenario A: 500 Cotton Tees with a 1-Colour Logo for a Conference in 3 Weeks	Screen Printing	Large order with a simple design. Screen printing is cost-effective and perfect for bold designs on cotton. With a 3-week timeline, it’s the most efficient choice.
Scenario B: 20 Polo Shirts with a Small Logo on the Left Chest	Embroidery	Small order with a premium finish. Embroidery adds a high-quality look to polos and is great for smaller runs. It also offers long-term durability and brand prestige.
Scenario C: 75 Tote Bags with 2-Colour Logo, Pantone Match	Screen Printing	The design involves spot colours and Pantone matching. Screen printing is ideal for vibrant colours and large runs, making it the most cost-effective option for this scenario.
Scenario D: 30 Hoodies with Full-Colour Artwork	Embroidery	Full-colour artwork on hoodies benefits from embroidery's high-end finish. While screen printing could work, embroidery provides a more premium look and is more suitable for smaller, detailed logos on fabric like fleece.

4. Screen Printing vs DTG

Choosing between screen printing and DTG (Direct-to-Garment) depends on key factors like order size, design complexity, fabric type, and budget. Both methods have their strengths, but understanding when to use each can significantly impact cost, quality, and turnaround time.

The table below highlights the differences, helping you decide the best method for your branded merchandise, corporate gifts, or promotional products.

Factor	Screen Printing	DTG
Best for	Large runs, bold designs	Small runs, full-colour designs
Typical MOQ	100+ units	1–50 units
Setup Time	Longer (screen creation required)	Quick setup (digital file only)
Speed for Large Runs	Fast for large orders	Slow for large runs
Per-Unit Cost	CAD $5–12 (bulk orders)	CAD $12–25 (small runs)
Colour/Gradient Handling	Best for spot colours and simple designs	Excellent for full-colour and gradients
Pantone Matching	Excellent for accurate colour matching	Challenging with Pantone matching
Fabric Suitability	Best for cotton and poly blends	Best for cotton (not ideal for polyester or synthetics)
Dark Garment Handling	Requires an underbase for dark garments	Limited to light fabrics
Durability	Very durable with proper curing	Good durability on cotton, but can fade after multiple washes
Feel	Ink sits on top of the fabric, can be stiff	Ink soaks into the fabric, resulting in a soft feel
Special Effects	Limited to metallic inks, puff printing	Limited in texture effects
Sustainability	Can use water-based inks, but screens create waste	Minimal waste, no screens, but uses energy and ink

Real-World Scenarios: Screen Printing vs DTG

The choice between screen printing and DTG often depends on your specific project needs. Let's look at some real-world scenarios to help you understand when to choose one method over the other.

Real-World Scenarios: Screen Printing vs DTG

Scenario	Best Method	Why
Scenario A: 500 Cotton Tees, 1-Colour Logo for a Conference in 3 Weeks	Screen Printing	Large order with a simple design. Screen printing is cost-effective for large runs and delivers bold, durable prints on cotton.
Scenario B: 24 Polyester Jerseys with Full-Colour Logo, 4 Days	DTG	DTG is perfect for small runs with full-colour designs on polyester, and the quick turnaround fits the timeline.
Scenario C: 75 Tote Bags with 2-Colour Logo, Pantone Match	Screen Printing	Pantone matching and spot colours work best with screen printing for vibrant, accurate prints on a larger run.
Scenario D: 30 Hoodies with Full-Colour Artwork, 1 Week	DTG	For full-colour artwork on hoodies, DTG is the best choice for vibrant prints and quick processing on cotton fabrics.

Decision Guide: Screen Printing vs DTG

The decision between screen printing and DTG (Direct-to-Garment) depends on key factors such as order size, design complexity, and budget. Both methods have their advantages, but choosing the right one can significantly impact your cost and turnaround time.

In this guide, we’ll walk you through when to use each method based on your specific needs, so you can make the best decision for your next project.

Below is a simple 5-step outline to guide you through the decision-making process:

Step 1: Order Size and Budget

Choose Screen Printing When:

You’re ordering 100+ units. The setup cost is spread across many items, making it more cost-effective for large runs.

Choose DTG When:

You have small orders (1–50 units) or require on-demand printing. There’s no setup cost for each unit, making it more economical for small batches or custom designs.

Scenario:

• 100+ tees → Screen Printing
• <50 units → DTG

Step 2: Artwork Type and Colour Complexity

Choose Screen Printing When:

• Your design uses bold spot colours, simple logos, or Pantone matching. It's perfect for clean graphics and solid fills.
• Full-colour designs can be done, but complex gradients and photos are harder to print efficiently.

Choose DTG When:

You need full-colour prints, gradients, or photo-realistic designs. DTG is great for detailed, multi-colour artwork without any extra cost per colour.

Scenario:

• Simple logos, 1–2 colours → Screen Printing
• Photos or complex art → DTG

Step 3: Fabric Compatibility

Choose Screen Printing When:

• You're working with cotton, polyester blends, or heavier fabrics like hoodies or tote bags.
• Ideal for dark fabrics, just make sure you’re using an underbase for bold designs.

Choose DTG When:

100% cotton is your go-to fabric. DTG performs best on light-coloured cotton and is perfect for soft, photo-quality prints.

DTG can work on polyester, but pretreatment is needed, and results on dark polyester are less than optimal.

Scenario:

• Cotton or blends, dark fabric → Screen Printing
• Light-coloured cotton → DTG

Step 4: Durability and Care

Choose Screen Printing When:

You need maximum durability for your prints. Screen printing holds up well after 30–50 washes (depending on care) and is the preferred method for workwear and high-use apparel.

Choose DTG When:

You’re looking for softer prints that don’t add texture. DTG prints typically last for 25–30 washes, but may fade faster than screen printing if not properly maintained.

Scenario:

• Heavy-use garments → Screen Printing
• Soft, cotton tees with photo prints → DTG

Step 5: Speed and Turnaround Time

Choose Screen Printing When:

You have large orders and medium lead times (5–7 business days). Once the screens are set up, printing can be done quickly in large quantities.

Choose DTG When:

You need fast turnaround and small quantities (1–50 items). DTG is much faster for smaller runs, and you don’t need to wait for screens to be created.

Scenario:

• 500 tees in 2 weeks → Screen Printing
• 20 custom tees in 3 days → DTG

7. Expert Advice on Screen Printing VS Heat Transfers:

Expert take: If you give me a choice, I’ll almost always pick screen printing. It’s cleaner, sharper, and feels like part of the shirt, not something sitting on it. And in most cases, it’s cheaper too.

But… if the artwork is super complex and a heat transfer will genuinely produce a better result, I’m not sentimental about it. I’ll choose whatever makes the final product look its best.

Anup Gupta
President
Cuyahoga Falls, Ohio

Expert take: If you asked me to choose, I'd choose screen printing every time. It's more durable, looks great, and your customers will notice the difference.

Heat transfers? I only reach for them when the order is tiny or the shirt is something people will wear once or twice. In the long run, great quality is what brings people back.

Kassi Porter Fuhrman
Owner
Shawnee, Kansas

Expert take: If you’re choosing between the two, go with screen printing. It’s just more durable. With heat transfers, the ink has to move through an extra layer. With screen printing, the ink goes straight onto the garment. Less translation. Better results. Every time.

Donna LoPinto
Owner and President
Tarrytown, New York

Expert take: We use both methods in our shop. Screen printing, when done right, lasts almost forever. But a well-made, fully screen-printed transfer can hold up for years, too, and for certain jobs, it’s the smarter choice.

Just one warning: avoid those hybrid “part digital, part screen” transfers. They look plasticky, feel cheap, and won’t make anyone happy. Stick to a true screen-printed transfer or go direct screen. Your customers will feel the difference.

Brooke Bradley
Owner and Operator Santa Maria, California

8. FAQs

 

Which is better, DTF or screen printing?

Screen printing is better for bulk orders, bold spot colours, and long-lasting prints, while DTF is better for small runs and full-colour artwork with gradients. Screen printing scales well and offers Pantone accuracy, but DTF handles detail with no colour limits.

What kind of ink is used for screen printing?

Screen printing typically uses plastisol, water-based, or discharge inks. Ink choice depends on fabric and brand requirements.

How many washes will screen print last?

A properly cured screen print typically lasts 40-70 washes, depending on the ink, fabric, and care. Plastisol lasts the longest, while water-based inks are more durable with proper curing.

How to wash a shirt after screen printing?

Wash screen-printed shirts inside out with cold water and mild detergent. Avoid bleach and high-heat drying. Air dry or use low heat to extend the life of the print.

Can I reuse a screen for screen printing?

Yes, screens can be reused by removing the old emulsion and reclaiming the mesh. As long as the mesh is clean and undamaged, the screen can be reused for new designs, helping maintain print quality and reduce long-term production costs.

What fabric is not good for screen printing?

Waterproof, silicone-coated, and highly stretchy athletic fabrics are not good for screen printing because the ink may not adhere properly. Test the material first to ensure optimal print durability.

What lasts longer, sublimation or screen printing?

Sublimation usually lasts longer because the dye becomes part of the polyester fabric. Screen printing also lasts well when cured properly, especially on cotton.

What is better, heat transfer or screen printing?

Heat transfer is better for small quantities or multi-colour artwork, while screen printing is better for bulk orders needing durability and Pantone-matched branding.

What is the best angle for screen printing?

A 45-degree squeegee angle is widely recommended because it balances ink flow and pressure, creating clean, consistent prints. Lower angles push more ink; higher angles deposit less.

How thick should emulsion be for screen printing?

Most screen printing emulsions perform best at around 4-20 microns above the mesh, depending on the type of ink you use and the level of detail in the artwork. Maintaining an even coat is important, and using the scoop coater at about a 45-degree angle helps maintain a consistent thickness across the screen.

What is the best size for screen printing?

A typical full-front screen print is 10–12 inches wide, while a left-chest logo is 3–4 inches. Choose a size that keeps your design visible without affecting comfort or durability.

How much pressure do you apply when screen printing?

Apply even, moderate pressure, just enough for ink to pass cleanly through the mesh. Too much pressure smudges; too little leaves gaps. Use smooth, controlled strokes.

What is the standard mesh size for screen printing?

Standard mesh sizes range from 110 to 160 for most apparel printing. Lower mesh counts (110) allow more ink for bold, opaque prints, while higher counts (156–160) work better for fine lines and detail. Choose your mesh based on artwork complexity and the fabric you’re printing on.

Is screen printing cheaper than sublimation for 200 shirts?

Usually yes, for 200 units with a simple 1-colour design on cotton, screen printing becomes more cost-effective due to lower per-unit cost at scale.

Which lasts longer, screen print or heat press?

Screen prints typically last longer, especially when cared for properly, while heat press may wear over time.

Is DTG more durable than screen printing?

Screen printing is generally more durable for long-term use, especially on cotton and polyester blends. DTG is good for full-colour prints, but may not last as long as screen printing, particularly on frequent washes.