DTG vs. Screen Printing vs. Embroidery: What's the Difference?
By The Merch Counter team · Updated · 2 min read
DTG (direct-to-garment) prints ink straight into the fabric like an inkjet printer, handles full color and has no setup cost, so it's the standard for print-on-demand shirts. Screen printing pushes ink through a stencil, one screen per color; it's cheapest per shirt in big batches but has setup costs and minimums. Embroidery stitches your design in thread; it looks premium and suits hats and aprons, but needs simple designs.
Side by side
| DTG | Screen printing | Embroidery | |
|---|---|---|---|
| How it works | Ink sprayed into fabric | Ink pushed through a stencil | Thread stitched in |
| Colors | Full color, gradients, photos | One screen per color | Limited thread colors |
| Setup cost | None | Per color, per design | Digitizing per design |
| Minimum order | One | Usually dozens | Varies; one with POD |
| Cost per item | Same at any quantity | Very low in big batches | Higher |
| Feel | Soft, part of the fabric | Ink sits on top; can feel thicker | Raised, textured |
| Best fabrics | Cotton | Most | Caps, heavier fabrics |
| Fine detail | Good | Good | Limited |
| Best for | Print on demand, small runs, many colors | Large bulk orders, simple designs | Hats, aprons, polos, premium look |
DTG (direct-to-garment)
A specialized printer applies water-based ink directly into the fabric. For dark garments, a white underbase is printed first so colors stay bright.
Good: no screen setup, any number of colors, photos and gradients, perfect for one-at-a-time orders. Watch for: works best on cotton; very fine details on heathered fabrics can look slightly softer; dark garments may feel a little less soft because of the underbase.
This is the main method for print-on-demand apparel, including on The Merch Counter.
Screen printing
A stencil (screen) is made for each color — a three-color logo needs three screens. Ink is pushed through each screen in turn.
Good: very durable, vivid colors, lowest cost per shirt in large quantities. Watch for: setup costs per color, minimum orders, every shirt in the batch is the same, and you pay for stock up front.
This is what most local print shops do for bulk orders.
Embroidery
Your design is converted to a stitch file ("digitized") and sewn with thread.
Good: premium look and feel, very durable, the classic choice for caps. Watch for: needs simple, bold designs; small text and fine lines don't stitch well; fewer colors, because every color needs its own thread.
On The Merch Counter, embroidered caps, aprons and tees are available, and each is labeled by technique in the catalog so you know which you're choosing.
Which should you use?
- Selling online with no inventory? DTG for apparel, embroidery for hats.
- Ordering 100+ identical shirts for an event? Screen printing is likely cheaper.
- Want a premium hat or apron? Embroidery.
- Design with lots of colors, gradients or a photo? DTG.
- Simple one- or two-color logo in bulk? Screen printing.
Related: Print on Demand vs. Bulk Ordering · Print-on-Demand Merch guide