4 Types of Custom T Shirt Printing Methods and How They Can Help Grow Your Business

$562 million.

That’s the revenue that original design t-shirt sales reached in 2019.

The profitability of this niche continues to expand, showing the popularity of t-shirts among consumers.

Custom t shirt printing is relatively inexpensive, functional, and long-lasting promotional materials. They increase brand positivity and recognition.  Here are a few ways you can use custom t shirt printing as marketing tools.

As this industry has grown for obvious reasons, so have the types of shirt printing.

Find out about a few different methods to learn more about the industry and find what matches your needs.

Most Common Types of Shirt Printing: Heat Press

Don’t get confused — many types of shirt printing involve heat and pressure.

Heat (often around 350 degrees) and pressure allow the image to transfer from one medium to another. The combination of these two elements bonds ink/ vinyl to the material of the shirt.

Heat press methods use either transfer paper or vinyl. You peel away transfer paper after heat pressing, while vinyl is the medium of the image itself.

A great example of a vinyl heat press is letters on a sports jersey. They’re less flexible than other methods of shirt production but are used for basic shapes and letters.

The heat press process is better for smaller orders like one or two sample pieces. This is especially true when using vinyl, as each shirt needs its own cut outs.

Here’s a look into another process that uses heat press.

Dye Sublimation

Also called dye-diffusion or digital sublimation, this method relies on a reaction caused by high heat.

A reverse image of the final design goes onto transfer paper through a gel ink printer. The ink is water-based and as heating occurs, it transforms from a solid to a gas.

Common dyes sublimate at 350 degrees but it can range between 380 and 420 degrees Fahrenheit. When the ink is in gas form, it bonds with the shirt at a molecular level and then re-solidifies.

The only way this method works is if you use 50-100% polyester or other types of polymer material. Additionally, it’s better for lighter-colored fabrics. We have several 100% Polyester fabrics here that you can choose from.

With dye sublimation, you can print oversized images all over the t-shirt.

Another added benefit is that because the dye bonds to the t-shirt at a molecular level, the images are permanent. The dye does not build up and the colors don’t fade like other printing methods.

It’s a relatively new practice for t-shirt printing but has been around in industrial and high-end commercial settings. Now, dye sublimation is popular in photo booths, medical imaging, and security operations (such as I.D. tags).

Another new method of printing is DTG.

Direct-to-garment (DTG)

DTG still uses heat as a final sealant, like the previous methods discussed, but the main process of production is direct printing.

As the name implies, a large specialized printer moves a design directly to the shirt. Transfer paper and vinyl aren’t involved.

Then the design is heat-cured on a press for 60 to 90 seconds.

Production using this method can be high-quality and high resolution, but it all depends on the quality of the printer.

This technology is expensive and not ideal for small business startups.

While it seems like a good option to choose from companies that have the equipment, that may not be the case.  DTG shirts aren’t ideal for mass production, as it’s a slower method compared to others.

Additionally, results work better with natural fibers and lighter color t shirts that are 100% Cotton.  The ink used is relatively thin so it doesn’t show up as well across dark material.

If you’re ordering large quantities of synthetic material t-shirts, this isn’t the option for your business.

Instead, you’ll want to go for the final method discussed: screen printing.

Screen Printing

The art of screen printing dates back to 960 A.D. in Asia. Back then screens consisted of silk rather than the finely woven polyester or nylon ones we use today.

Also known as serigraphy, screen printing is unique compared to other methods in that it doesn’t use high pressure. It doesn’t necessarily use heat, either, unless needed for making certain types of ink permanent.

A computer design prints onto transparency paper to create a stencil on a nylon or mesh screen. Before the stencil transfers to the screen, the designer must coat the screen with emulsion.

Then, the image transfers from the transparency paper onto the screen through light exposure.

The parts of the screen where color won’t transfer gets taped over. The negative space is the only part that the ink will go through.

Then it’s printing time. The shirt lays beneath the screen as the designer pours ink onto the top of it. Using a squeegee, the designer evenly disperses the ink across and into the shirt.

The ink dries quickly. Once one layer of color exists, the designer repeats the process until finished. This is due to the fact that one screen is only used for one color.

The results are professional, durable, and cost-effective for bulk designs.

This is because once you have all the screens necessary for a design, it’s then easy to replicate in high quantities.

Custom T shirt Printing Professionals

This explanation of types of shirt printing is merely a brief look into the processes.  The methods are complex and highly technical.

Not only that but each one has various expenses and learning curves.

While it’s great to know how to make something, oftentimes it’s most efficient to rely on professionals.

To ensure you receive top quality products that are worth your time and money, check out our various printing services.