Exploring T-Shirt Printing Techniques For Custom Creations

There are several methods for printing designs onto T-shirts, each with its own advantages and disadvantages. The most common types of T-shirt printing include:

- Direct-to-garment (DTG) printing

- Screen printing

- Heat transfer printing

- Direct-to-film (DTF) printing

- Dye sublimation or all-over printing (AOP)

- Vinyl printing

- Plastisol transfer printing

The best method for you will depend on various factors, such as the fabric type, the complexity of the design, the number of shirts you want to print, and your budget.

Direct-to-Garment (DTG) Printing

The DTG printing process involves several steps. First, the artwork is prepared and checked for any issues that may impact the printed result, including compression artefacts, colour profiling, and colour correction. Next, the garment is pre-treated with a solution that helps the ink bond to the fabric. This is typically done using a machine that sprays liquid onto the fabric. The pre-treated garment is then placed on a platen, a flat platform designed to hold the fabric in a fixed position during printing.

The printing process itself uses specialised aqueous inkjet technology, with print heads jetting or spraying ink directly onto the textile. DTG printing allows for a wide range of colours and can handle complex designs with multiple colours or photographic details. The ink sinks into the fabric, resulting in a smooth, seamless finish that is not noticeable to the touch.

After printing, the garment is cured using a heat press or forced air dryer to set the ink and make it permanent. This step ensures that the design will withstand repeated washings. DTG printing is best suited for natural fabrics such as cotton, polyester, and cotton/polyester blends, and produces the best results on light-coloured garments.

One of the key advantages of DTG printing is its ability to handle small orders and single shirts cost-effectively. Unlike screen printing, there are no long setup or clean-up processes, making DTG ideal for printing a single shirt for a minimal cost. Additionally, the digital nature of the process allows for sharper prints with higher resolution compared to traditional methods.

DTG printing also offers a large range of colour options and can accommodate both mass production and short production runs. It is a relatively simple process that is highly detailed and long-lasting. However, it is limited to cotton and white garments and may not be cost-effective for large-scale production.

Screen Printing

The Process

• Create the artwork: The quality of the final print is dependent on the quality of the original artwork. Each colour in the design will require a separate screen, so it is important to separate the colours and clean up the artwork before printing. Programs like Illustrator, Photoshop, or Procreate can help with this process.
• Print a film positive: Print the artwork onto a film positive transparency, which will be used to burn the image into the silk screen.
• Expose the image onto a screen: Coat a mesh screen with light-sensitive emulsion and then expose it to light. The emulsion hardens where the light hits it, and the unexposed areas are rinsed out, leaving space for the ink to pass through.
• Set up the screen printing press: Prepare the screens on the printing press, with each colour having its own screen and arm.
• Set up the T-shirt: Apply pallet adhesive to the platen to ensure the T-shirt stays in place, and then load it onto the press.
• Print the design: Flood the screen with ink and then use a squeegee to push or pull the ink across the screen and onto the T-shirt. Repeat this process for each colour.
• Cure the ink: Use a conveyor dryer or flash dryer to cure/set the ink so that it lasts through multiple washes.

Advantages and Disadvantages

Heat Transfer Printing

There are several subtypes of heat-press printing, including dye sublimation, direct-to-film (DTF) printing, and vinyl heat transfer or heat transfer vinyl (HTV).

Dye sublimation, also known as all-over printing (AOP), is a popular type of shirt printing. The designs are digitally printed onto a special heat transfer paper using a sublimation printer and then transferred onto t-shirts with a heat press. Dye-sublimation uses heat to transform dye-based ink into a gas, bonding it with synthetic materials like polyester. This process differs from other heat transfer methods as it embeds the ink deeply into the fabric, resulting in vibrant, durable prints.

Direct-to-film (DTF) printing is another heat transfer method that combines water-based inks with a polyethylene terephthalate (PET) film transfer sheet. The design is printed onto the PET film and then applied to the garment using adhesive powders and a heat press. DTF printing works with almost any fabric type and offers an unlimited colour range. However, it creates a less natural feel and is a slower printing process.

Vinyl heat transfer, or HTV, uses thin sheets of polyurethane with a heat-activated adhesive backing. The vinyl easily transfers to t-shirts when the machine is pressed at the right temperature and pressure. HTV is commonly used for sports jerseys and promotional items.

The heat transfer printing process typically involves the following steps:

• Creating a design on a computer using graphic design software.
• Printing the design onto heat transfer paper using inkjet, sublimation, screen print, or pigment ink.
• Trimming the printed image using a vinyl cutter, if necessary.
• Warming up the heat press to the appropriate temperature, usually between 340°F to 365°F (171°C to 185°C).
• Adjusting the pressure according to the thickness of the fabric.
• Setting the time for the heat press machine based on the type of heat transfer method.
• Positioning the t-shirt and transfer paper on the heat press.
• Pressing the product to transfer the design.
• Removing the film once the timer goes off.

Direct-to-Film (DTF) Printing

DTF printing offers several advantages. Firstly, it allows for printing on a wide range of fabrics, making it a versatile option. Secondly, it produces bright and beautiful prints with enhanced colour vibrancy. Thirdly, it can be applied to any base colour shirt. Additionally, DTF printing is highly resistant to wear and tear, making it a durable option.

However, there are also some drawbacks to consider. DTF printing can only be used on smaller items like t-shirts, cushion covers, or face masks. The print may feel plastic-like, which creates a less natural feel. Furthermore, the process is more complex and time-consuming than some other printing methods, such as dye sublimation or direct-to-garment (DTG) printing.

The DTF printing process can be broken down into three main steps. Firstly, the PET film is prepared and placed in the DTF printing machine, where the design is printed in colour and then covered with a white layer. Secondly, an adhesive powder is applied, and the film is heated to prepare it for fabric transfer. Finally, the fabric is pre-pressed, and the design is transferred using a heat press.

Overall, DTF printing is a versatile and durable option for printing on various fabrics, but it may not be suitable for larger items or those seeking a more natural feel.

Dye Sublimation or All-Over Printing (AOP)

Dye sublimation, also known as all-over printing (AOP), is a popular t-shirt printing method that allows for unique and creative designs. Unlike other printing techniques such as direct-to-garment (DTG) and screen printing, dye sublimation is not limited to specific print areas. It allows for the entire product surface to be printed on, making it ideal for repetitive patterns and all-over designs.

The dye sublimation process involves three main steps. First, a digital image file of the desired design is created. This file is then printed in reverse on special heat transfer paper using a sublimation printer. Finally, the paper is pressed onto the t-shirt and heated under pressure, turning the ink into a gas that bonds with the fabric fibres. This unique process results in vibrant and durable prints that are deeply embedded into the fabric.

One of the key advantages of dye sublimation is its ability to cover the entire shirt, including seams and other areas that are typically challenging to print on. It is also known for its long-lasting results, as the dyes fully penetrate the fibres of synthetic materials, particularly polyester. This method is not suitable for cotton or dark-coloured t-shirts, as the ink tends to "bleed" and will not bond properly.

Dye sublimation is generally more expensive than other printing methods, but it offers the ability to create eye-catching and distinctive designs that cover the entire shirt. It is a popular choice for those looking to add all-over patterns and designs to synthetic fabric t-shirts.

Frequently asked questions