When it comes to custom apparel printing, one of the most frequent questions is whether Direct-to-Garment (DTG) printing is a cost-effective solution for small orders. This query is especially relevant for small businesses, independent creators, and individuals looking for customized apparel without breaking the bank. Let’s explore this question in detail to help you decide if DTG printing aligns with your needs.
Direct-to-Garment (DTG) printing is a process that uses specialized inkjet technology to print designs directly onto fabric. Unlike traditional methods like screen printing, DTG does not require the creation of stencils or screens, making it ideal for detailed and colorful designs. Here are some of the key advantages of DTG printing:
To determine whether DTG printing is cost-effective for small orders, let’s break down the key cost considerations:
Per-Unit Cost: With DTG, the cost per print is consistent, whether you’re printing one shirt or fifty. This is because there are no setup fees, making it ideal for smaller quantities.
Ink Usage: Designs with more colors or higher ink saturation may cost slightly more due to increased ink consumption.
DTG works best on 100% cotton garments for optimal ink absorption. The cost of the garment itself will influence the overall price of the order.
Premium-quality shirts will naturally increase the per-unit cost.
For small orders (1-50 units), DTG is highly cost-effective as there’s no need to spread setup costs over a large quantity.
For larger orders, the consistent per-unit cost of DTG may become less competitive compared to methods like screen printing.
The weight of a shirt, often measured in grams per square meter (GSM) or ounces per yard, affects its printability. Lightweight fabrics (e.g., 4.5 oz) are breathable and soft, but heavier fabrics (e.g., 6.0 oz) are more durable and absorbent. For DTG printing, a medium-weight shirt (5.0–5.5 oz) strikes the ideal balance between comfort and print quality.
A smooth, tightly woven fabric is critical for DTG printing. Rough or uneven surfaces can cause ink to pool or spread, resulting in blurry designs. Pre-shrunk and ring-spun cotton are excellent choices because they provide a smooth, consistent surface.
AS Color is a favorite among DTG professionals for its premium-quality 100% cotton tees. The AS Color Classic Tee (5026) stands out with its:
Material: 100% combed cotton for exceptional smoothness.
Weight: 6.5 oz, ideal for both comfort and durability.
Fit: Modern, relaxed style that appeals to a wide audience.
Hanes offers excellent options for budget-conscious projects without compromising quality. The Hanes Beefy-T (5180) is particularly popular for DTG printing:
Material: 100% ring-spun cotton for a soft feel.
Weight: 6.1 oz, making it highly durable and absorbent.
Versatility: Available in a wide range of colors and sizes.
The Gildan Softstyle 64000 is a staple in the DTG community for its affordability and print quality:
Material: 100% ring-spun cotton for a smooth finish.
Weight: 4.5 oz, providing a lightweight yet durable feel.
Fit: Semi-fitted design, perfect for retail-quality custom shirts.
Comfort Colors is known for its heavyweight, garment-dyed shirts that produce stunning prints with a vintage vibe. The Comfort Colors 1717 is a top choice:
Material: 100% ring-spun cotton with a soft, broken-in feel.
Weight: 6.1 oz, offering excellent durability.
Colors: Unique, pigment-dyed options for standout designs.
Dark-colored shirts often require a pre-treatment solution to enhance ink adhesion and vibrancy. Shirts made from 100% cotton respond best to pre-treatment, ensuring sharper and more vibrant designs on darker fabrics.
To maintain print quality over time, always choose high-quality shirts with pre-shrunk fabric. This reduces shrinkage and distortion after washing, preserving both the print and the garment’s shape.
Light Shirts: Easier to print on and require less pre-treatment.
Dark Shirts: Offer a striking contrast but need pre-treatment and white ink underbase for best results.
Selecting the best shirts for DTG printing involves more than just picking a brand; it’s about understanding the fabric composition, weight, and texture that work best for your designs. While 100% cotton shirts from brands like AS Color, Hanes, Gildan, and Comfort Colors are top choices, the final decision depends on your budget, audience, and print requirements.
Looking to create high-quality custom shirts? Explore DTG printing services or shop for premium blanks from Things Above Custom Apparel to bring your designs to life. Let’s make your next print project your best one yet!
