In today’s fashion and merchandising world, custom t-shirts have become a staple for brands, events, teams and individuals alike. But how are t-shirts printed? That question sparks curiosity in many who appreciate the artistry and technology behind turning a plain garment into a vibrant canvas. In this comprehensive blog post, we will delve into the principal methods of t-shirt printing, explore the advantages of each technique, and shine a spotlight on why here at Get Tees we champion Direct to Garment printing for unparalleled quality and versatility.
How are t-shirts printed?
Before diving into individual processes, it helps to understand the general concept: t-shirt printing involves depositing ink or dye onto fabric in patterns or images that are both durable and visually appealing. Across the industry, five core methods dominate:
- Screen Printing
- Heat Transfer Printing
- Dye Sublimation
- Direct to Garment (DTG) Printing
- Direct to Film (DTF) Printing
Each of these techniques carries its own set of benefits and ideal use‑cases. Read on to discover which one suits you best – whether you’re looking for small bespoke runs or large‑scale production.
Screen Printing
How are t-shirts printed using screen printing? This traditional approach has been around for decades and remains the workhorse of the industry.
- Process
- A mesh screen is coated with a light‑sensitive emulsion.
- A stencil of your design blocks out areas not intended to receive ink.
- Ink is pressed through the mesh onto the shirt using a squeegee.
- The garment passes through a dryer to cure the ink.
- Benefits
- Durability: Screen‑printed inks bond well with fabric, resulting in long‑lasting prints that resist fading and cracking.
- Vibrancy: Thick layers of ink create bold, vivid colours, especially on darker fabrics.
- Cost‑Effectiveness for Large Runs: Once screens are prepared, running hundreds or thousands of prints incurs minimal extra cost per unit.
- Versatility: Works reliably on cotton, polyester, blends, and even canvas or wood.
Ideal for: Bulk orders (50+), simple designs with limited colours, and merchandise where longevity is paramount.
Heat Transfer Printing
For smaller runs or highly detailed artwork, many ask, how are t-shirts printed when they require photographic quality? Heat transfer methods might be the answer.
- Process (Vinyl Transfer)
- A plotter cutter cuts your design from coloured vinyl film.
- The excess vinyl is weeded away, leaving only your artwork.
- A heat press applies high temperature to transfer the vinyl onto the fabric.
- Process (Digital Heat Transfer)
- A digital printer prints your design onto specialised transfer paper.
- The image is heat‑pressed from paper to garment, embedding the ink in the fibres.
- Benefits
- Detail and Gradient: Digital transfers capture fine details and gradient hues that would be challenging in traditional screen printing.
- No Minimum Order: Perfect for one‑off or small batches – particularly in personalised gifts and prototyping.
- Quick Turnaround: Design to print can happen within hours, ideal for rush orders.
- Low Setup Cost: No expensive screen preparation, reducing upfront investment.
Ideal for: Custom one‑offs, small order runs, complex multi‑colour designs, or photographic reproductions.
Dye Sublimation
When polyester or specialised blends are involved, you might wonder how are t-shirts printed so that the design becomes part of the fibre itself? Dye sublimation is the answer.
- Process
- A sublimation printer uses heat‑activated inks to print the design onto coated transfer paper.
- The garment is placed under a heat press at high temperature (around 200°C).
- Under heat and pressure, the ink turns into gas and bonds permanently with the polyester fibres.
- Benefits
- All‑Over Coverage: Enables edge‑to‑edge printing with no limits on print size or shape.
- Soft Hand Feel: Because the ink becomes part of the fabric, there is no added layer on top – the design never feels stiff.
- Exceptional Durability: Colours remain brilliant and resist cracking or peeling over time.
- Breathability: Garment breathability is unaffected, making it ideal for sportswear.
Ideal for: Performance apparel, sports kits, and all‑over printed garments on polyester or polyester‑rich blends.
Direct to Garment (DTG) Printing
At Get Tees we often get asked, how are t-shirts printed when you want full‑colour, photographic prints done swiftly and affordably on cotton? Our answer: Direct to Garment printing.
- Process
- The t‑shirt is pre‑treated with a primer, ensuring ink adherence.
- A DTG printer (similar to an inkjet) sprays water‑based pigment inks directly onto the fabric.
- The garment enters a conveyor dryer to cure the inks, ensuring wash‑fastness.
- Benefits
- Unlimited Colours: Print full‑colour, high‑resolution artwork without worrying about colour separations.
- No Minimum Orders: Perfect for single shirts, samples, or micro‑batches.
- Soft Finish: Water‑based inks soak into the fibres for a natural, breathable feel.
- Eco‑Friendly: Water‑based inks are non‑toxic and biodegradable, reducing environmental impact.
- Speed and Flexibility: Designs can be changed or personalised on the fly, making it ideal for custom print‑on‑demand services.
Ideal for: Small to medium runs, highly detailed designs, personalised apparel, and eco‑conscious brands.
Direct to Film (DTF) Printing
A newer player, how are t-shirts printed with ultra‑flexible print options on diverse fabrics? Enter Direct to Film.
- Process
- The design is printed onto a specialised PET film using DTF inks.
- A powder adhesive is applied onto the printed film.
- The film is heat‑cured to set the powder.
- The design is transferred to the garment via heat press.
- Benefits
- Fabric Compatibility: Works on cotton, polyester, blends, nylon, leather, and even dark textiles.
- Soft Feel and Stretch: Transfers remain flexible and crack‑resistant even on stretchy fabrics.
- Durable Prints: Exceptional wash and rub fastness, often outperforming heat transfers.
- Economical for Complex Designs: No need for multiple screens or mats, making multi‑colour or gradient artwork cost‑effective.
Ideal for: Diverse fabric types, smaller runs with varied designs, and applications where stretch and softness matter.
Our Choice: Direct to Garment Printing at Get Tees
So, how are t-shirts printed? At Get Tees, we pride ourselves on using Direct to Garment printing for the majority of our orders. Here’s why:
- Outstanding Detail & Colour
DTG offers photographic quality prints, faithfully reproducing every shade and gradient in your artwork. - Unmatched Personalisation
From single‑shirt orders to bespoke giveaways, we can switch designs instantly without downtime for screen changes. - Eco‑Friendly Workflow
We use water‑based pigment inks certified to Oeko‑Tex Standard 100. Our pretreatment solutions are solvent‑free, ensuring a smaller carbon footprint. - Soft & Durable Finish
The inks bond at a fibre level and cure to a smooth finish. Labels, neck prints and one‑off sleeves feel as soft as the rest of the shirt. - Speed & Efficiency
Fast turnarounds mean you receive your order in days, not weeks. Ideal for tight deadlines or last‑minute events.
By choosing DTG, our clients enjoy the best of both worlds: the premium feel of traditional inks and the flexibility of digital production.
Most Popular Printing Method in the UK
If you’ve ever wondered how are t-shirts printed most commonly across Britain, the answer remains: Screen Printing. Despite the rise of digital processes, screen printing still holds pride of place for several reasons:
- Heritage & Trust: Established studios and brands trust screen printing for its proven track record.
- Cost Efficiency: For orders of 50 garments or more, the per‑unit cost of screen printing undercuts DTG or heat transfer.
- Vibrancy on Dark Fabrics: Unmatched opacity of plastisol inks makes designs pop brilliantly against black or navy tees.
- Longevity: High‑volume events, uniforms and club kits in the UK rely on screen‑printed durability through countless washes.
However, in recent years we’ve seen DTG steadily eating into that market share, especially amongst small businesses and creators who prize on‑demand production without minimums.
Benefits of Each Method Summarised
| Method | Key Advantages | Best For |
|---|---|---|
| Screen Printing | Durability, vibrancy, cost‑effective for bulk | Large orders, simple designs |
| Heat Transfer | Photographic detail, low setup cost, no minimums | Prototypes, one‑offs, small batches |
| Dye Sublimation | All‑over coverage, soft hand‑feel, sportswear | Polyester sports kits, performance wear |
| DTG Printing | Unlimited colours, personalisation, eco‑friendly | Small to medium runs, intricate artwork |
| DTF Printing | Fabric versatility, stretchable prints, durability | Mixed fabrics, stretchy materials |
Conclusion
In essence, how are t-shirts printed? comes down to selecting the right method for your needs: whether you require the time‑tested robustness of screen printing or the cutting‑edge flexibility of Direct to Garment printing. Here at Get Tees, we leverage the latter to guarantee stunning, eco‑conscious, and supremely comfortable garments every time.
Ready to bring your designs to life? Contact Get Tees today and discover how we can transform your concepts into wearable art with our DTG expertise. Let’s answer the question how are t-shirts printed? the right way – with passion, precision, and a dedication to quality.