T-Shirt Printing: Creative, Quick, And Easy

T-shirt printing is a popular way to express yourself and decorate your clothing. There are many different methods for printing designs onto T-shirts, each with its own advantages and disadvantages. Some common T-shirt printing methods include screen printing, direct-to-garment (DTG) printing, heat transfer printing, dye-sublimation printing, and vinyl printing. Screen printing, for example, involves creating a stencil and using a nylon mesh screen to apply ink to the T-shirt. This method is ideal for high-volume orders and can produce vibrant colours, but it can be messy and requires a lot of space. On the other hand, DTG printing is similar to printing on paper and can produce high-quality, full-colour prints, but it is only suitable for light-coloured T-shirts, typically made from cotton. Heat transfer printing involves printing a design onto special paper and then using heat and pressure to apply it to the T-shirt. This method is fairly straightforward, but it can be slower than other methods and works best on light-coloured T-shirts. Overall, the best method for printing T-shirts depends on the specific needs and constraints of the project.

Direct-to-Garment (DTG) Printing

DTG printing offers unmatched detail and vibrant colours, resulting in high-quality prints. The process is cost-effective, with no minimum order requirements, making it a popular choice for those looking to print products on demand. Unlike screen printing, DTG requires minimal setup time and is less labour-intensive, making it ideal for small-quantity orders.

The DTG printing process typically involves a pre-treatment step, where a pretreatment solution is applied to the garment to enhance the adhesion and vibrancy of the inks. This can be done through hand spraying or using a pre-treatment machine. After the pre-treatment dries, the garment is placed in the DTG printer, where the design is digitally printed. All garments, except white ones, first receive a white underbase to enhance the final print's vibrancy. Once the underbase is printed, the DTG printer adds the rest of the colours, using a mix of cyan, magenta, yellow, and black inks, just like an inkjet printer.

After printing, the garment undergoes a final drying process to cure the ink, helping it resist washing and preventing dulling. This can be done using a conveyor dryer or a heat press, depending on the scale of the operation. DTG printing offers the advantage of printing on demand with no minimum order quantities, allowing people to order as few or as many products as they like.

DTG printing is best suited for natural fabrics like cotton, which enhance absorption and improve print quality. However, advancements in technology are making it possible to use DTG printing on a wider range of materials. With its high-quality prints, flexibility, and environmental benefits, DTG printing has become a popular choice for custom t-shirt printing and other similar fabric items.

Screen Printing

The process begins with the creation of artwork. This can be done by the customer or the printer. The quality of the artwork will determine the quality of the final print, so it is important to get this stage right. If the design includes multiple colours, these must be separated to create different screens for each colour.

Once the artwork is finalised, a film positive is printed. This is a transparency, like an overhead projector slide, which is used to burn the image onto the screen. The film positive is printed in black ink and then used to expose the image onto the screen. The screen is coated with light-sensitive emulsion and then dried, before the film positive is placed on top and exposed to light. The emulsion hardens where the light hits it, and the black area of the film blocks light from reaching the emulsion, leaving a soft, unexposed area. The screen is then rinsed with water, washing away the soft emulsion and leaving the design on the screen.

The screens are then set up on the printing press, with one screen per colour. The press consists of a base with printing platens and colour arms. The more colour arms, the more colours can be printed at once. The screens must be registered, or lined up, correctly so that the colours print properly.

Before printing, pallet adhesive is applied to the platen to ensure the shirt stays in place. The shirt is then loaded onto the press and the printhead is aligned. The screen is flooded with ink and then pushed or pulled across the screen with a squeegee to deposit the ink onto the shirt. This process is repeated for each colour.

Finally, the printed shirt is cured using a conveyor dryer or flash dryer to ensure the ink sets properly. The temperature required varies depending on the ink used.

Heat Transfer Printing

• Design Creation: The first step is to create a design on a computer using graphic design software. This involves arranging and modelling text and images to be printed.
• Printing the Design: The design is then printed onto heat transfer paper using inkjet, sublimation, screen print, or pigment ink. This paper is responsible for transferring the design onto the T-shirt.
• Trimming: If needed, the printed image is trimmed using a vinyl cutter to ensure clean edges. Any part that is not cut away will appear on the final product.
• Warming the Heat Press: The heat press is heated to a temperature between 340°F and 365°F (171°C to 185°C). The specific temperature and pressure settings will be provided by the transfer supplier.
• Adjusting Pressure: The pressure applied will depend on the fabric's thickness. Generally, less pressure is applied to thicker materials.
• Setting the Time: Different heat transfer methods require different press durations. For vinyl transfer, the press time is 7-15 seconds, while digital transfer takes 10-20 seconds. Dye sublimation transfer requires 25-30 seconds.
• Positioning: The T-shirt is placed on the platen, and the heat transfer paper is positioned face-up in the desired location on the T-shirt.
• Pressing: The handle of the heat press is pulled down to close it and apply pressure and heat.
• Removing the Film: Once the timer goes off, the heat press is opened, and the film is removed.

There are two main heat transfer methods: vinyl heat transfer and digital heat transfer. Vinyl heat transfer, or heat transfer vinyl (HTV), uses thin sheets of polyurethane with a heat-activated adhesive backing. This ensures the design easily transfers to the T-shirt when the right temperature and pressure are applied. Digital heat transfer, on the other hand, uses regular transfer paper and is similar to printing a photograph onto a garment.

Dye Sublimation or All-Over Printing (AOP)

The process of creating an AOP garment typically involves printing the fabric first and then cutting and sewing the product. This "cut and sew" method means that the design is applied to the fabric before it is turned into a garment. However, there are some exceptions, such as socks. It is important to note that AOP garments are hand-sewn, so some pattern markings used as guides during the sewing process may be visible on the inside of the garment.

AOP is an excellent option for those who want to customise their products with large, seamless designs. It offers exceptional coverage, allowing you to create a consistent design that covers both the front and back of a shirt or other items. This technique results in a flawless finish, making it a popular choice for companies and designers who want their products to stand out.

However, there are some limitations to consider when using AOP. Firstly, it is recommended to avoid placing important design elements in the seam, collar, or cuff area, as they may be cut off or shifted during the manual cut and sew process. Secondly, wrap-around designs should be avoided, as it is challenging to achieve perfect alignment across seams or zip areas. Finally, centred placement of designs is not guaranteed and may shift during the production process.

Vinyl Printing

There are various types of vinyl printing, including cut vinyl and PermaPress vinyl. Cut vinyl is used for simpler designs, whereas PermaPress vinyl is used for more complex, multicoloured artwork. PermaPress is a long-lasting printing method that involves digitally printing full-colour images onto a lightweight, high-quality vinyl decal. The decal is then cut out precisely and pressed onto the T-shirt using heat. This method ensures that the image lasts for years, rather than fading after a few washes.

There are many companies that offer vinyl printing services, including RushOrderTees, Amazon, Custom One, Custom Ink, I Am T Shirts, and VistaPrint. These companies offer a range of vinyl printing options, as well as other T-shirt printing methods such as screen printing, direct-to-garment (DTG) printing, and embroidery.

When ordering vinyl-printed T-shirts, it is important to consider the number of shirts needed, the type of shirt, the number of ink colours, and any personalisation required. These factors will impact the final price of the order.

Frequently asked questions