When you’re ordering custom apparel, you’ll hear two printing options over and over again: screen printing and digital printing.
Basically, they do the same job, getting your design onto fabric. But they work in very different ways and shine in different solutions.
- Screen printing pushes thick, vibrant ink through a stencil-covered mesh screen. It takes extra setup time, but you get ultra-durable prints and perfect Pantone colour matching. Ideal for big, uniform orders.
- Digital printing works like an inkjet photo printer for garments. It sprays CMYK ink straight onto the fabric, needs no screen, and handles photographs, gradients, and one-off names with ease—best for small batches, rush deadlines, or highly detailed artwork.
As you read on, keep in mind this rule of thumb:
“Lots of identical pieces? Go Screen. Fewer, personalized, or photo-rich pieces? Go digital.”
Screen Printing
It has a very simple but effective process, involving the creation of a stencil on a mesh screen, then pushing ink through the open areas of the screen onto he fabric. It creates a clean, sharp design with vibrant colours.
Pros of Screen Printing:
- Cost-Effective for Larger Runs: This method offers great value for larger quantities. The more you print, the lower the per-shirt cost becomes.
- Durability: Known for their long-lasting quality, screen prints make ideal workwear, uniforms, and anything that needs to last, even with frequent washes.
- Vibrant & Opaque Inks: You get eye-catching finishes for your designs that need to stand out with bold colors because this method uses thicker ink.
- Pantone Matching: Screen printing allows you to achieve precise coloring if you need exact color matching. This is especially ideal if you’re using Pantone shades.
Special Effects & Flexibility
- Speciality Inks: You can experiment with textures and finishes like glitter, glow-in-the-dark, or metallic inks.
- Ideal for Simple Designs: Screen printing works best for designs with fewer colours or less intricate details.
Cons of Screen Printing
- Not for Complex Designs: If your design has many colours, gradients, or intricate details, then screen printing becomes tricky and more expensive.
Digital Printing
Digital printing is a relatively new method that involves spraying ink directly onto the fabric with a printer head, much like how a photo is printed. This process requires no stencils, which means faster turnarounds.
Pros of Digital Printing:
- Cost-Effective for Small Runs: If you only need a few shirts or personalised items, digital printing is the most affordable choice.
- Perfect for Detailed Designs: Digital printing excels at capturing intricate details, fine lines, and gradients—something that can be tough for screen printing.
- Wide Colour Range: With CMYK (Cyan, Magenta, Yellow, and Black) ink, digital printing can produce a wider range of colours and smooth gradients, making it perfect for artwork with multiple shades.
- Personalisation Made Easy: Want to add a name or a unique number to each shirt? Digital printing allows for easy customisation, without the extra cost or effort.
Cons of Digital Printing:
- Durability: While digital prints look great, they may not hold up as well over time as screen prints, especially after multiple washes.
- Cost for Larger Orders: For larger quantities, digital printing can become more expensive than screen printing, as it doesn’t offer the same cost-saving benefits for bulk production.
- Not Ideal for Special Effects: Unlike screen printing, digital printing is limited when it comes to special finishes like glitter or metallics.
Key Differences at a Glance
Feature | Screen Printing | Digital Printing |
Process | Mesh screen per colour | CMYK inkjet onto fabric |
Durability | Ultra‑tough; raised hand‑feel | Good, softer feel |
Colour Matching | Spot‑on Pantone | Near match, CMYK limits |
Cost Efficiency | Best ≥ 100 pcs | Best ≤ 50 pcs |
Detail / Photos | Limited | Photo‑real |
Personalisation | Costly | Variable‑data ready |
Special Effects | Puff, glitter, metallic | Few effects |
Turnaround | Slower setup, fast run | Fast overall |
Which Method Fits Your Project?
Both methods have clear strengths. Your ideal choice depends on your project size, design complexity, timeline, and budget.
Here’s a handy guide:
If you… | Go with… | Because… |
Need 1,000 event tees with a 2-color logo | Screen Printing | Lowest unit cost after setup |
Want 25 photo tees for a Kickstarter | Digital Printing | No setup fees and photo-quality prints |
Require exact Pantone 186 C red | Screen Printing | Spot-color accuracy |
Forgot your deadline was yesterday | Digital Printing | Quick turnarounds, even same-day possible |
Final Checklist Before You Order
- Order Size: More than 100? Screen printing is more economical.
- Artwork Complexity: Gradients or photos? Choose digital. Solid logos? Choose screen printing.
- Special Inks Needed?: Puff, metallic, or glow-in-the-dark? Screen is the only option.
- Eco Goals: Digital for small runs and low water usage; screen for reusable setups on large batches.
- Turnaround Time: Tight deadline? Digital is your sprinter.
Final Take
Both methods have their place, but if you’re after shirts with long-lasting prints, bold colours, and unbeatable value for bulk orders, screen printing stands out. It’s the trusted go-to for teams, events, and brands that want consistency and quality.
At Apparel Pro, screen printing is what we do best. From crisp logos to custom Pantone matches, we deliver results that hold up and stand out.
Ready to get started? Let’s bring your vision to life, one screen at a time.
Frequently Asked Questions
What lasts longer, screen printing or digital printing?
Screen printing. It’s more resistant to fading, cracking, and washing.
Does screen printing crack over time?
Not easily. When done properly, it stays vibrant and intact for years.
How long does digital print last?
With proper care, it lasts 20–40 washes, but may fade or crack sooner than screen prints.
What is the best image type for t-shirt printing?
Vector files (like .AI or .EPS) are ideal. High-res PNGs also work well for digital prints.
What is the lifespan of a screen print?
Typically 50+ washes—often outlasting the shirt itself.
What lasts longer, screen printing or digital printing?
Screen printing. It’s more resistant to fading, cracking, and washing.
