Screen Printing vs. Embroidery vs. DTG: Which Is Right for Your Order?
By Rasheed Omar, Founder of Wearmill · June 2, 2026 · 6 min read · Last updated June 2026
Screen printing, embroidery, and DTG (direct-to-garment) are the three main ways to put a logo on a product. Each method has trade-offs in cost per unit, durability, color range, and minimum order size. The right choice depends on what you're printing, how many you need, and what the final product needs to look like.
Quick comparison
| Screen Printing | Embroidery | DTG | |
|---|---|---|---|
| Best for | Bulk orders, simple designs | Hats, polos, professional look | Small runs, photo-quality art |
| Cost per unit (100 units) | $7.99 | $12.99+ | $15-25 |
| Setup fee | $25/color (waived at 144+) | $35 digitizing (waived at 96+) | None |
| Minimum order | 24 units | 24 units | 1 unit |
| Colors | 1-6 colors (per screen) | Up to 15 thread colors | Unlimited (full color) |
| Durability | 50+ washes | Outlasts the garment | 30-50 washes |
| Best products | T-shirts, hoodies, tote bags | Hats, polos, jackets | T-shirts, hoodies |
| Turnaround | 5-7 business days | 5-7 business days | 5-7 business days |
Screen printing
Screen printing pushes ink through a mesh stencil onto the fabric. Each color in your design requires a separate screen. This makes it the cheapest option for large runs with simple designs (1-3 colors), but the per-screen setup cost means it gets expensive for small quantities or designs with many colors.
Use screen printing when: you need 48+ units with a 1-3 color logo. The unit price drops significantly at higher quantities. At 576+ units, a Gildan tee with a 1-color print runs about $6.49/unit.
Skip screen printing when: you have a full-color photo, need fewer than 24 units, or want a different design on every shirt.
Embroidery
Embroidery stitches your design directly into the fabric with thread. It looks more polished and professional than printing, which is why it's the standard for hats, polos, and corporate wear. The texture and dimension of stitched thread gives a premium feel that ink can't match.
Use embroidery when: you're branding hats, polos, quarter-zips, or jackets. It's also the right choice when you want a logo that looks upscale, like for corporate gifts or uniforms.
Skip embroidery when: your design has fine detail, gradients, or more than 15 colors. Small text (under 6pt) doesn't stitch well. It's also more expensive per unit than screen printing at high volumes.
DTG (direct-to-garment)
DTG works like an inkjet printer for fabric. It sprays ink directly onto the garment, which means it can reproduce full-color photos, gradients, and complex artwork with no color limitations. There's no setup fee, so it's the most cost-effective option for small runs.
Use DTG when: you have a complex, full-color design, need fewer than 48 units, or want each shirt to be different (like personalized names).
Skip DTG when: you need 100+ units of a simple 1-2 color design. Screen printing will be cheaper per unit at that volume.
Decision guide
- 100 t-shirts, 1-color logo: Screen printing. Cheapest per unit, most durable.
- 48 embroidered hats for a team: Embroidery. The only method that works well on structured hats.
- 12 shirts with a full-color photo: DTG. No setup fee, unlimited colors, low quantity.
- 500 polos for corporate uniforms: Embroidery. Looks professional, outlasts the garment.
- 200 event tees, 2-color design: Screen printing. Best price-to-quality ratio at this volume.
FAQ
Can I combine methods on the same order?
Yes. You can screen print the back of a t-shirt and embroider the front left chest, for example. Each method is priced separately.
Which method lasts the longest?
Embroidery is the most durable. The thread is stitched into the fabric and won't fade with washing. Screen printing holds up for 50+ washes when properly cured. DTG lasts 30-50 washes with proper care (wash inside out, cold water).
What if I don't know which method to use?
Send us your logo and tell us what product and quantity you're thinking. We'll recommend the best method and quote all applicable options so you can compare.
Related guides
- How Much Do Custom T-Shirts Cost in 2026? — full pricing breakdown by quantity and blank
- How to Order Custom T-Shirts (Step-by-Step) — the full ordering process explained
- Screen Printing in Houston, TX — what to look for in a local printer
Not sure which method is right?
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