Choosing a decoration method is one of the most common sticking points when ordering custom or branded apparel. Screen printing, embroidery, and heat transfer are the three main options, and each one suits a different type of job. Here is how they actually compare, and when to use each.
Screen Print
Screen printing works by pushing ink through a mesh stencil directly onto the fabric, one colour at a time. It gives bold, vibrant results and is one of the most popular methods in the industry because it dries quickly and can be shipped almost immediately.
The catch is the setup. Screen printing has a setup cost of 85 dollars minimum, since a new screen has to be made for every colour in the design. That cost gets spread across the order, so screen print becomes more cost effective the bigger the run is. It is a great option for large volume orders with simple, bold designs, but it is not always the cheapest choice for a handful of pieces.
Embroidery
Embroidery stitches the design directly into the fabric using thread, giving that classic raised, premium finish you see on polos, caps and jackets. It has a similar 85 dollar minimum setup cost for digitising the design, but unlike screen print, embroidery still works well on small orders. The quality and durability it delivers make it worth it even at lower quantities, which is why it remains the go to choice for corporate uniforms and premium branded apparel regardless of order size.
Heat Transfer
Heat transfer covers a few different techniques, but the standout right now is Direct to Film, or DTF. Unlike traditional heat transfer methods, DTF has no setup cost at all, which makes it the most accessible option for small print runs. If you only need a handful of pieces or you are testing a design before committing to a bigger order, DTF is usually the smartest choice.
Which One Should You Choose
The minimum order quantity is the same across all three methods, so quantity alone will not decide this for you. It comes down to setup costs and finish. For large runs with simple designs, screen print is hard to beat on cost. For a premium, long lasting look regardless of quantity, embroidery is the way to go. And for small runs or one off pieces where you do not want to wear a setup fee, DTF heat transfer is the most practical option.
You can see examples of all our decoration methods, including screen print, embroidery and heat transfer, on our Deco Methods page. If you are still not sure which is right for your project, get in touch and we will point you in the right direction.
