There are various Types of Printing methods using conventional and digital technology. Six of the most demanding printing techniques Apparitex used in clothing line in United States are:

1. Direct-to-garment DTG Printing
2. Screen printing
3. Dye sublimation printing
4. Heat transfer vinyl printing
5. Plastisol transfer printing
6. Airbrushing

The two most widely used printing methods are DTG and screen printing. We’ll examine each of these shirt printing styles below. We will go over each method’s benefits and drawbacks.

What is DTG Printing?

Direct-to-garment (DTG) printing puts ink directly onto clothes. This is different from other printing methods that use screens or transfer papers to get the ink onto the clothes.

DTG uses a particular printer that applies water-based inks to shirts using a four-step process:

• A digital art file containing a design is developed and saved on a computer that is linked to the printer.
• The sample is then ready for printing. To prevent white ink from spreading, blending, or fading into colored inks, a pretreatment solution is used. To provide a smoother printing surface, the shirt is subsequently cured using a heat press or air dryer to flatten the fibers.
• Before feeding the sample into the printer, it is oriented over a platen, which is a flat platform.
• The ink is dried using a forced air drier or heat press after the sample is printed so that it will adhere to the garment even after several washes.

With DTG printing, you may alter your designs without making new screens or stencils because it uses images straight from computer files. Complex designs can be printed with sharpness, color, and high resolution. The most common sample textiles, such as cotton, polyester, and blends of cotton and polyester, can be used with DTG. The best results are obtained when using it on natural textiles like cotton.

Many people believe that DTG is the greatest printing technique because it is more environmentally friendly. There are no harmful chemicals present in the water-based inks used in DTG printing. The quantity of waste is decreased because designs are printed directly onto the cloth, eliminating the need for extra materials like screens or paper.

Although DTG printers can cost over $10,000, this technology is perfectly suited for print-on-demand applications. Direct-to-garment printing methods become more economical when partnered with a reliable print on demand provider, which also helps cut down on excess inventory and overproduction.

Pros:

• Printing directly into clothing can handle intricate patterns with several colors or fine photographic detail.
• DTG inks give the fabric a velvety texture by sinking into it.
• Environmentally friendly materials and inks are used in direct-to-garment printing.
• DTG printing can swiftly generate any number of shirts.

Cons:

• Direct-to-garment printing is not as good for polyester samples, but it performs best on cotton samples.
• Compared to screen-printed shirts, DTG samples are less resistant to washing and sunshine.
• DTG printers are pricey, but by utilizing a print on demand (POD) service, you can lessen this expense.

What is Screen Printing?

Using a mesh partially obscured by a stencil printing shape, ink is applied to shirts using the screen printing technique, commonly known as silkscreen printing. Screen printing is categorized as an indirect technique for producing various shirt prints when it is done with a mesh material.

• Silkscreen printing uses a seven-step process:
• A computer file is printed onto a clear acetate film, which will be used as a stencil, to produce the design.
• An emulsion is used to prepare one or more screens; when exposed to light, it hardens and blocks off the region around the design that will be printed. For every color in the design, you must use a single screen.
• The emulsion hardens when the screen is exposed to light.
• The hardened emulsion is removed to make a stencil.
• Position the sample beneath the screen on a printing board after adjusting the screen on a printing press. To imprint the design on the sample, the screen is lowered onto the printing board, ink is placed within, and the ink is forced down with a blade or squeegee
• After printing, the ink is cured using a heat gun, heat press, flash drier, or conveyor dryer.
• Screens and stencils are needed for samples with numerous colors.

Formerly, one of the most often used techniques for printing shirts was screen printing. However, for modest quantities of shirts, screen printing is less economical than DTG due to the time required to produce stencils and screens. When printing big quantities of hundreds or thousands of samples, screen printing is still valuable.

Pros:

• Vibrant prints are produced by screen printing for straightforward patterns with few colors.
• Screen-printed graphics hold up well after several washing cycles.
• For large print runs, screen printing is an affordable option.

Cons:

• Complex color patterns and high-resolution images are not ideal for screen printing; it takes a lot of time to put up stencils and screens.
• Screen printing is only economical when done on a large scale.
• Compared to DTG printing techniques, screen printing is less environmentally friendly because it wastes materials and ink.

What is Dye Sublimation Printing?

One of the interesting printing techniques that you can use on every part of the garment is dye sublimation, sometimes referred to as all-over printing (AOP). Dye sublimation, for instance, can cover areas like seams or print repeating patterns. Unlike DTG and silkscreen printing methods, which apply ink to specific printing locations on flat shirt surfaces, this method is different.

The dye sublimation method uses a three-step process:

• A digital picture file is used to build the sample design.
• The image is printed backwards on transfer paper using a specific printer.
• The ink is transferred to the shirt by pressing the paper on the sample, heating it under pressure until it becomes gaseous, and then cooling it.

Sublimation works beautifully on synthetic fabrics such as polyester. However, this printing method doesn’t bond ink to cotton.

Pros:

• A sample can be printed entirely using dye sublimation.
• Sublimated inks give the garment a smooth appearance and feel by blending into the cloth.
• Shirt designs that are sublimated won’t peel or fade.
• Samples made via dye sublimation have a breathable quality.

Cons:

• Sublimation is more expensive than other printing methods
• It is ineffective with cotton or dark samples

What is Heat transfer vinyl printing (HTV printing)?

Transfer of heat Vinyl printing—also referred to as iron-on printing—transfers graphics from sheets made of vinyl or plastic. Using reusable tape, you color one side of the sheet and then cut it into shapes for your design. You apply an adhesive that has been heated to the opposite side.

HTV uses a five-step process:

• The cut pattern can be made digitally or by hand.
• An HTV cutting machine or hand labor are used to cut out the pattern.
• Cutting (weeding) is the process of removing extra material.
• A heat press or iron is used to apply the design on the sample.
• The image is removed by peeling away the tape.

Stiff designs are produced by the vinyl used in HTV printing. Materials needed for heat transfer printing must not melt in a hot environment. It’s not very visible against dark backdrops. These kinds of clothes prints are frequently used for the lettering on sports jerseys.

Pros:

• Easy for beginners.
• Inexpensive.

Cons:

• Design cutting takes time, slowing production.
• Vinyl creates stiff designs.
• Doesn’t work well on dark backgrounds.
• It is limited to fabrics that can withstand the heating process.
• Unsuitable for large-scale production.

What is Plastisol Transfer Printing?

Plastisol screen printing is an indirect screen printing method where samples are inked using a plastic-based transfer sheet. Instead of using a mesh screen, heat transfer paper is used to apply inks in this more straightforward kind of silkscreen printing.

Screen printing and plastisol printing share many procedures, however there are some important distinctions. The design is applied to the transfer paper instead of the sample directly, which is the biggest distinction:

• Created designs and screens are set up as in screen printing, except you do the design in reverse.
• The transfer paper is run through a conveyor dryer to remove moisture.
• The transfer paper is placed under the screen.
• Ink is applied to the transfer paper.
• The transfer paper is applied to the sample with a heat press.
• Adhesion powder is applied to the sample to reduce blurring. Remove any excess powder.
• The ink is heated to gel in a conveyor dryer.
• A heat press is applied.
• The transfer paper is peeled off.

Plastisol transfer printing is helpful for situations like printing during live events where you need to know how many samples you’ll need ahead of time. Gelled transfer papers can be stored before heating and then heat-pressed to create shirts when needed.

Plastisol transfer sheets are available for creating unique effects such as glosses and textures. Plastisol heat transfer creates long-lasting designs that are resistant to fading and breaking. Large orders, half-tones, or photographic pictures cannot be processed using this method.

Pros:

• High-quality.
• Durable designs.
• Special effects options.
• Store transfer paper for later printing.

Cons:

• Requires skilled, time-consuming preparation.
• Not suitable for bulk orders.

What is Airbrushing?

Airbrushing is among the manual types of printing on clothes, which uses a small spray painting tool. The process involves four steps:

• Using a temporary, light adhesive, a stencil is made from a material, like pennant felt, and adhered to a sample. For various colors, you can use more than one stencil.
• Paint is loaded into the airbrush, which is then connected to an air supply. Use different paints for patterns with several colors.
• The airbrush applies paint on the shirt, one color at a time, using the sample on a board and an easel. As desired, you can apply manual touches.
• After the paint dries, the pattern is protected with paperback paper, and the paint is fixed with an iron.

Applying graphics via airbrushing offers total creative flexibility and is a simple and affordable process. Airbrushed designs aren’t durable, and they can’t accommodate fine detail. Large orders are not a good fit for airbrushing because of the physical labor required.

Pros:

• Easy to start and do yourself.
• Inexpensive.
• Allows creativity.

Cons:

• Low-quality designs.
• Low durability.
• Labor-intensive.
• Unsuitable for bulk orders

Which printing method should you select for your brand?

When choosing among the different printing methods for your business, consider the design complexity, fabric type, order volume, and budget.

• Direct-to-garment (DTG) is perfect for intricate, colorful designs on cotton fabrics but may be a bit costlier for bulk orders.
• Screen printing excels in vibrant, long-lasting prints for larger batches, making it cost-effective for bulk orders.
• Dye sublimation works best for all-over prints on polyester fabrics, offering vivid and durable results.
• Direct-to-film (DTF) printing offers versatility across various fabrics, providing bright, detailed prints.
• Plastisol transfers are great for high-quality prints on diverse materials and allow glossy or textured finishes.
• Vinyl printing is ideal for text-based designs like sports jerseys and offers durability and flexibility in design placement.
• Though limited in design complexity, embroidery adds sophistication and is incredibly durable.
• Airbrushing allows creative, hand-crafted designs for unique, small-scale projects.

Whether you prioritize cost-effectiveness, manufacturing volume, fabric compatibility, or design complexity, your decision should be in line with the particular requirements of your sample business. Your choice of approach is essential to defining the product quality and style of your brand in the printing industry because each has a distinct appeal and applicability.

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