Big Brands' T-Shirt Printing Secrets Revealed

T-shirt printing is a vast industry with thousands of small and big companies offering a wide variety of printing solutions. When it comes to large companies, they tend to opt for screen printing, heat transfers, or direct-to-garment (DTG) printing methods. Screen printing is a traditional method that has been used for a long time and is suitable for bulk printing. It produces durable and long-lasting results but can be time-consuming and messy. Heat transfers, on the other hand, are a more modern approach, offering quick and easy printing but may result in lower quality. DTG printing is similar to using an inkjet printer, producing high-quality, full-colour prints directly on the t-shirt. Each method has its advantages and disadvantages, and the choice depends on factors such as cost, quality, and production time.

Direct-to-garment (DTG) printing

The DTG printing process involves several steps:

Pre-Treatment

The pre-treatment process is essential for DTG printing. It helps multi-colour designs adhere better to the garment, prevents the ink from washing off, and enhances the vibrancy of colours. There are two ways to apply pre-treatment: hand spraying, which involves manually spraying the garment with a sprayer, and using a pre-treatment machine, which automatically treats the shirt.

White Underbase

After the pre-treatment, a white underbase is applied to all garments except white ones to enhance the vibrancy of the final print.

Adding Colours

Once the underbase is printed, the DTG printer adds the remaining colours. Like a regular inkjet printer, it uses a mix of cyan, magenta, yellow, and black inks.

Drying and Curing

After printing, the garment needs to dry for the final time to cure the ink and prevent dulling. This can be done using a conveyor dryer (commonly used by industrial manufacturers) or a heat press for smaller businesses.

DTG printing offers several advantages, including high-detail image quality with unlimited colours, no minimum order quantity, and environmental friendliness. However, it may not work on certain textiles, has limited application surfaces, and is not optimal for bulk orders due to its slower printing speed.

When choosing a printing method, it's important to consider factors such as order quantity, design complexity, fabric type, and turnaround time. While DTG excels in high-quality, small-batch, and intricate designs, other methods like screen printing may be more suitable for bulk orders and simpler designs.

Screen printing

To begin the screen-printing process, a stencil is created with the desired design. This stencil is then placed over the t-shirt, and ink is pushed through a mesh screen onto the fabric. This process is repeated for each colour in the design, with each colour dried before the next is applied. This technique creates durable designs that withstand wear and washing.

Companies like Custom Ink offer screen printing services, allowing customers to create their own designs or use provided templates. They also provide assistance with the design process, ensuring that the final product meets expectations.

Overall, screen printing is an effective method for large-scale t-shirt printing, offering efficiency, durability, and customisation options to create unique and long-lasting products.

Heat transfer printing

One of the benefits of heat transfer printing is that it can be done with standard equipment, such as an inkjet or laser printer, and does not require specialised machines or inks. This makes it a popular choice for those looking to print t-shirts at home or on a small scale. Additionally, heat transfer printing is simple and straightforward, making it a good option for beginners.

However, there are some drawbacks to this method. Large designs may crack and split, and the excess background or edges of the transfer paper may also be transferred onto the shirt. The design may also be noticeable to the touch.

To achieve the best results with heat transfer printing, it is important to use the correct type of transfer paper and ink. For inkjet printers, regular inkjet ink can be used, while sublimation printing requires specialised sublimation ink and transfer paper. It is also important to note that the design should be mirrored or flipped before printing, to ensure it is not transferred onto the shirt backwards.

Overall, heat transfer printing is a convenient and affordable option for t-shirt printing, particularly for small businesses or individuals looking to create custom t-shirts at home.

Dye sublimation printing

The dye-sublimation process involves printing an image in reverse onto a special poly-coated substrate, which is then transferred onto the fabric using heat and pressure. During this process, the dye turns into a gas, penetrates the fabric, and solidifies into the fibres, permanently dyeing the fabric.

Dye-sublimation printing is ideal for an all-over print on t-shirts, and can be used on both the front and back of a shirt. It is perfect for company events, family reunions, sports teams, and more. The shirts are machine washable, with the prints being fade-resistant and safe to be washed.

There are several advantages to dye-sublimation printing. The images are permanent and will not peel or fade. The dye has a soft feel and does not build up on the fabric. The colours are vibrant due to the transparent dye bonding to the fibres, and the image can be printed all over the item, right up to the edge.

However, there are also some disadvantages. There may be shade variance in the print colour from shirt to shirt, and creases in the apparel during printing will leave blank spots. There may also be slight imperfections in the look and registration from the front to the back, and blemishes on common areas, usually with dark colours gasing onto lighter colours.

Direct-to-film printing (DTF)

DTF printing is advantageous due to its ability to produce film positives, resulting in sharp and detailed prints with high resolution and crisp edges. It is also a speedy and cost-effective process, making it ideal for day-to-day operations and small print runs or custom designs. Additionally, DTF printing can be applied to various fabrics, including cotton, polyester, silk, nylon, and blends, making it a popular choice for heavy-duty sportswear and outdoor apparel.

However, there are some drawbacks to consider. DTF transfers may not last as long as traditional screen-printed garments and tend to fade faster. The ink sits on top of the fabric, giving the shirt a rougher feel compared to screen-printed shirts where the ink soaks into the garment. DTF is also not suitable for large production runs as it requires individual transfers for each shirt, making it time-consuming and expensive for large orders.

Overall, DTF printing is a valuable technique for creating detailed and vibrant prints on a range of fabrics, especially for small-to-medium-sized businesses or those targeting custom and boutique markets.

Frequently asked questions