When ordering custom t-shirts, you’ll often hear the terms screen printing and digital printing. These are the two most common methods used in custom apparel production. While they work very differently, the goal is the same: a durable, great-looking print.

At Bolt Printing, the printing method is not something customers need to choose. It’s determined by factors like order quantity, garment style, and artwork. This article explains what each method is and why one may be used over the other.

Screen Printing

Screen printing uses mesh screens and ink to apply a design to a shirt. Each color is applied separately, which makes this method especially efficient for larger quantities.

Why it’s used

• Best for medium to large orders
• Produces bold, vibrant colors
• Highly consistent across a full run
• Supports specialty inks and more print locations
• Lower material costs and labor efficiencies make screen printing increasingly cost-effective as quantities increase..

Because setup time is involved, screen printing becomes more cost-effective as order size increases.

Digital Printing (DTG)

Digital printing, also known as direct-to-garment printing, applies ink directly to the fabric using a digital file. There are no screens or stencils involved.

Why it’s used

• Ideal for small orders
• Handles complex artwork and photos well
• Minimal setup required
• Digital printing uses higher-cost materials and prints one shirt at a time, making it slower and less economical for larger orders.

This method is often used when screen printing would not be practical due to order size or garment limitations.

How the Print Method Is Chosen

The primary factor in determining print method is quantity, followed by garment style and artwork.

• Larger orders typically use screen printing
• Smaller orders are usually digitally printed
• Certain garments or print locations may require one method over the other

The goal is always the same: choose the process that delivers the best quality and value for your specific order.

The Bottom Line

Screen printing and digital printing both play an important role in custom apparel production. Each method is used where it performs best.

You don’t need to decide which printing method to use. Once you're ready, you can start your order in our design studio, and the print method is automatically selected based on your order.