The Art Of T-Shirt Graphics: Printing Techniques Explored

There are several ways to put graphics on a T-shirt, and the method you choose will depend on the equipment you have available, the colours involved, and the complexity of the design. For instance, if you're creating a T-shirt with a detailed design, a full-front design placement is a versatile option. If you're looking for a quick, one-time print, transfer printing is a good option. This involves printing your design onto transfer paper and ironing it onto your T-shirt. For a more professional finish, you could try direct-to-garment (DTG) printing, which uses modified inkjet technology to apply water-based inks onto the fabric.

Direct-to-garment (DTG) printing

The process of DTG printing is similar to printing a document from a home or office printer. It involves using a computer with graphic design software to create or upload a design, which is then sent to the DTG machine. The printer driver provides instructions to the machine on what to print.

DTG printing typically requires pre-treating the garment with a pre-treatment machine or solution to enhance the bonding of the inks to the fabric. This step is especially important for white ink on dark garments. The pre-treatment is heat-pressed into the garment, causing the fibres to lay flat and creating a smoother surface for printing.

Once the garment is pre-treated and dried, it is positioned on the platen system of the DTG printer and locked into place. The printing process begins, with the ink jetted or sprayed directly onto the fabric. After printing, the garment is cured using a heat press to ensure the design adheres properly.

DTG printing offers several advantages, including high-quality and high-resolution prints, a shorter setup and cleanup process compared to screen printing, and the ability to print single shirts cost-effectively. It is suitable for natural fibres such as cotton, bamboo, hemp, and linen.

The first commercially available DTG printer, named "Revolution," was introduced in 1996, revolutionising the garment printing industry and making it more accessible and efficient.

Direct-to-film (DTF) printing

Step 1: Preparing the Film

A PET film is placed in the DTF printing machine, where the entire design is printed in colour. Then, the machine prints a white layer over the entire image, completely covering the first layer. After that, an adhesive powder is uniformly applied onto the wet ink, and the film is heated to prepare it for fabric transfer.

Step 2: Pre-pressing Fabric and Using a Heat Press

With the PET film preheated, the fabric receiving the design is dehumidified and pre-flattened using a heat press. This ensures that the fabric is smooth and free of wrinkles before the design is transferred.

Step 3: Transferring the Design

The printed film is placed on the pre-pressed fabric, and the design is transferred using a heat press for 15 to 20 seconds at an average temperature of 165°C.

Step 4: Peeling the Film and Post-pressing the Fabric

Once the design has been transferred, the film is carefully hot peeled. The fabric is then flattened a second time in the heat press to improve the design's durability. After post-pressing, the garment is ready to be packed and shipped to customers.

DTF printing offers several advantages, including the ability to print on various fabrics, vibrant and durable prints, and a simple process that does not require pretreatment. However, it may not be the best option for large designs as it can be less breathable, and the printed area may be slightly more noticeable than with subliminal printing.

Screen printing

Step 1: Prepare the Artwork

Firstly, you need to have something to print on the T-shirt. Whether you design the artwork yourself or a customer brings it to you, all screen printing starts with some type of artwork. Remember that the better the quality of the artwork, the better the quality of the screen print. When screen printing T-shirts, you print one colour at a time. If you are printing multiple colours, you will need to separate the colours so you can create different screens for your design. You need one colour per screen.

Step 2: Printing Film Positives

Once the artwork is created and the colours are separated, the next step is to print a film positive. A film positive transparency is like an overhead transparency. You will use this film positive to burn the image onto a silk screen. Whatever you want to print on the T-shirt, you print it out in black ink on the film positive.

Step 3: Exposing the Image Onto a Screen

Once you have printed the films, it is time to make the screen. A screen printing frame consists of a wood or aluminium frame stretched with polyester mesh. The mesh holds the image onto the screen and lets ink pass through when you press it with a squeegee. You will need to coat the mesh with emulsion so that you can expose the design onto the screen. Before you coat the mesh, it needs to be cleaned with a special screen printing degreaser to ensure any dust, lint, or particles are washed off so no bumps or pinholes appear in your emulsion.

Emulsion is light-sensitive, so coating the screen is typically done in a darkroom with special light-safe yellow bulbs. After the screen is coated and dried, align the film positive onto the screen and expose it with a screen printing exposure unit or an exposure lightbulb for a specific amount of time. The screen hardens in the light, but the film positive or black area of the film blocks light from reaching the emulsion. This leaves the area of emulsion unexposed or soft. After the screen is exposed, simply rinse it with water. The soft part of the emulsion that was not exposed rinses out, leaving areas of the mesh open that reflect your design.

Step 4: Setting Up the Screen Printing Press

Before you are ready to start screen printing T-shirts, you need to set up the screens on your screen printing press. A screen printing press consists of a base that holds printing platens and a number of colour arms. A manual press can be as small as a 1-colour, 1-station, or as large as an 8-colour, 6-station. The more colour arms you have, the more colours you can print at one time. Likewise, if you have a higher number of printing stations, you can print more at a faster pace.

Step 5: Printing Your Shirts

Before loading the T-shirt onto the platen, you will want to make sure to apply pallet adhesive to the platen. This helps the T-shirt stick to the platen and not move around. Load your T-shirt onto the press and get your printhead aligned. Before locking the printhead into place above your T-shirt, make sure to flood the screen with ink.

Once the printhead is locked down, push or pull the screen-printing ink across the screen to deposit the ink onto the T-shirt. You may need more than one round of this, depending on how much ink was deposited. If you are printing multiple colours, follow these steps with your other screens.

Keep in mind that you may need to flash your T-shirt in between prints, especially if you are printing on dark garments with a white underbase. The flash dryer helps to cure/set the ink, giving you the ability to print another colour on top of your first layer. You also need to cure the print after you are completely done printing it. Curing is when the ink dries and sets in the garment. You can cure a T-shirt with a conveyor dryer or a flash dryer. The temperature at which the ink cures varies, so read the instructions on the ink container to learn the proper cure temperature. If a T-shirt isn’t cured properly, the ink will not last and the print will start to degrade.

Vinyl printing

There are two types of vinyl printing: printed vinyl and PermaPress vinyl. Printed vinyl is a simple process of printing your design onto vinyl, which is then cut out and pressed onto the t-shirt. PermaPress vinyl is a more high-quality and durable process. It involves digitally printing full-colour images onto a high-quality, lightweight vinyl, which is then cut out precisely and pressed onto the t-shirt. This method ensures that the image will last for years, rather than just a couple of washes.

To use vinyl printing, you will need to follow these steps:

Step 1: Choose the Right T-Shirt

Consider which colour will serve as the best background for your image. For example, if your image has rich colours and darker details, you should choose a light-coloured t-shirt. If your image includes softer tones and more subdued colours, a darker-coloured t-shirt would be better. Having a clear contrast between the image and the t-shirt will make the print stand out more.

Step 2: Prepare Your T-Shirt Design File

For your print to look good on the t-shirt, you must use a high-quality and high-resolution image file. You can use JPEG, PNG, and SVG files for the design. If you want to make adjustments to your image, there are plenty of free and low-cost photo editing tools you can use, such as Canva, GIMP, Fotor, or Pixlr.

Step 3: Apply Your File to the T-Shirt

Use a product creator or mockup generator to add your photo to the t-shirt and adjust its size and positioning. Once you’re done editing, select Preview to get a real-life mockup of your t-shirt.

Step 4: Order a Sample

If you’re making a printed t-shirt for yourself, now’s the time to order it. Do that by making a sample order of your t-shirt. After you’ve created your t-shirt and saved the design, choose the t-shirt size and the amount you want to order, add your shipping details, and wait for your custom t-shirt to arrive.

Step 5: Publish and Start Selling

If you want to sell your t-shirts online, connect to an online marketplace (e.g. Etsy, eBay) or create a stand-alone store (e.g. Shopify, Wix). Once you have your products and connect your account to an eCommerce store, start selling and spread the word. The print-on-demand service will handle the production and shipment of your item.

Heat pressing

To heat press a design onto a t-shirt, you will need a heat press machine, a blank t-shirt, and a transfer. The transfer can be printed at home using an inkjet printer and special transfer paper, or it can be purchased pre-printed.

• Set up your heat press machine: Plug in and turn on the heat press machine. Set the temperature according to the instructions on your transfer paper. Adjust the pressure based on the thickness of your t-shirt—a thicker t-shirt will require less pressure.
• Prepare your t-shirt: Place the t-shirt on the heat press, ensuring that the side you want to print on is facing up. Smooth out any wrinkles and avoid zippers, buttons, seams, or other obstructions.
• Prepare your transfer: If printing your own transfer, choose and reverse your desired image, then print it onto the transfer paper using an inkjet printer. Cut out the image, leaving no excess transfer paper.
• Heat press the design: Place the transfer face down on top of the t-shirt, ensuring it is inside the pressing area. Cover the transfer with a thin cloth if your heat press does not have a protective silicone pad. Close the heat press and press the start button. The timer will start, and the press will apply the correct amount of heat and pressure for the type of transfer you are using.
• Remove the shirt and transfer: When the timer goes off, open the press and remove the shirt. Peel off the transfer paper while it is still hot.

Frequently asked questions