I like to think that having the right fabric used when printing t-shirts is as important as the design itself used. This is the canvas underneath the printing that I will be doing. It is important to have the right fabric for the particular t-shirt printing method I will be using so that I can feel satisfied with the result and so will my clients.
How do you choose the best fabric for each t-shirt printing method? There are four major t-shirt printing methods used, namely: Screen Printing, Direct to Garment (DTG), Dye Sublimation, and Transfer Printing. Cotton is the preferred fabric for use with screen printing and DTG with some exception while polyester, cotton, and its respective blends can be worked on using the last two printing methods.
In this blog post, I will share with you the mechanics of how each printing method work, their fabric and other requirements, and more. But first, I want to discuss basic information about fabrics before we proceed any further.
What Are Fabric Types Used In T-Shirt Printing?
Image by stokedonprinting
There are three types of fabrics: natural, synthetic, and a blend of synthetic and natural fibers.
Natural fabrics can absorb liquid better. Synthetic fabrics are usually made of oil and plastic which by themselves and combined have a tendency to repel water.
Natural Fabrics
By name alone, these fabrics are sourced from nature specifically, from plants and animals. The process starts when fibers are removed from these natural sources and then made to go through a process such as weaving or threading to become a textile.
Abaca, coir, cotton, hemp, and pina are some of the well-known fabrics coming from plants while silk, camel hair, and cashmere are sourced from animals.
Synthetic Fabrics
As you may get from the name, these are fabrics made through a machine process. It has a reputation for having a plastic feel but advances in technology have made these fabrics breathable and viable. They even feel almost the same as the natural fabrics.
Flexibility and toughness are the calling cards of synthetic fibers and that is why they are used a lot in sportswear.
Good examples of synthetic fibers are nylon, polyester, and spandex.
Blended Fabrics
These are fabrics made by combining one or more fibers gathered from plant or animal sources. These fabric blends are designed to have a complementary effect on each other such as cotton (easy to wear) and polyester (does not wrinkle). The best qualities of each fabric are shown in the blended mix.
I know that it is important for textile producers to have a fabric that is easy to wear, looks good, and take care of for consumers to handle. The increased popularity of these blended fabrics was mainly because of these characteristics and it has resulted in increased sales for these manufacturers.
Over time, textile manufacturers have managed to come out with excellent designs and patterns using these blended fabrics.
Examples of these blended fabrics are cotton/polyester, nylon/wool, and cotton/linen.
Now that I have shared with you basic fabric information, let me show you why certain fabrics work best with each t-shirt printing method and more.
Screen Printing Method
Also known as silk screen printing, this method has been in practice for quite a while and continues to be popular because of the excellent quality of prints it keeps producing.
Fabrics
I recommend the use of natural fabrics for the reason that they can do a better job taking in liquids such as ink when using screen printing. You will see why this is so in the greater color detail produced by these prints.
100% ring spun cotton is the ultimate best fabric to use for its absorbent properties but you may also opt for 80%-20%, 70%-30%, and or on occasions, a 50%-50% cotton polyester blends. I like to keep the cotton percentage in the majority when blended fabrics are to be used.
One last thing, consider using a thicker material consistency in the fabric regardless as to whether pure cotton or cotton blends are to be used. If this is to be followed, more color vibrancy will show up since this fabric type can absorb more inks. Washed out prints usually happen when a lesser amount of inks are taken in by fabrics that are usually shinier and a finer variety.
Inks and Foils
Inks that should be used for screen printing method are usually of a thicker type for better absorption by the preferred fabric and which in this case is cotton.
Each color requires the use of separate screens for it is simply not doable applying multiple colors concurrently. If your artwork has three colors in it, then it simply means you will need to have three separate screens to handle printing.
When a dark-colored t-shirt is to be used for screen printing, a white underbase will have to be in place prior to printing the final design. If this is not taken into consideration, I am warning you that you will only get a faded and dull design printed.
There are other inks out there that will give you the desired effect being sought at in the prints. These inks are called specialty inks. Examples of these inks are:
Raised design – use high density or puff inks
Glow inside the dark – use inks called by the same name
Suede effect – use inks called by the same name
Weathered look – use vintage inks
Shine or sparkle effect – use metallic inks
Foils are stickers that are placed on the fabric itself. They are different from metallic inks but they can be utilized together with other types of inks especially when working with designs that are very detailed and complex.
Preparation and Printing
First, you must create artwork by using computer software such as Adobe Illustrator or Corel Draw. An image will then be printed using a transparency paper.
Afterward, you will need an emulsion solution and a mesh. The mesh should be covered with this solution in its totality and left to dry in a cold, dry room.
The artwork will then be fixed on top of the screen using a soft adhesive to hold it together in its place. Light will then be applied to this combination. The time duration for this application will be contingent on the setup you have made. Do-it-yourself (DIY) setups take about an hour while if you use an exposure unit, it may only take about 5 minutes to complete the job.
Once removed, a negative of the artwork will remain in place on top of the screen.
Your screen is now ready to be used for t-shirt screen printing. For this purpose, we shall discuss the manual printing process.
The t-shirt needs to be placed on an even and flat surface and then add the screen on top of it. Next, the ink will be arranged on the screen. A squeegee will be used to spread evenly this same ink on the screen.
Remove the screen and let the ink recently applied on the t-shirt dry out. You can also use a flash dryer to make this process faster.
Do remember that there is only a single color used per screen. If the artwork demands multiple colors, then separate screens would need to be used. The process described above would then have to be replicated over again.
Automatic Screen Printing Machine
If this process is quite messy for you, you have a big amount of orders coming in, and you have money, consider getting a machine to fo this job for you. This machine will allow you to save time and resources when doing the screen printing task and others.
They can handle various sizes of screens which gives your shop flexibility in the artwork conceptualized. They have a rotating design which enables you to maximize production.
Advantages of Screen Printing Method
Screen printing enables you to produce the design on your t-shirts that are very vibrant and rich and print it at a much faster rate compared to the printing methods.
The inks utilized for this method last for quite an extended period of time for they do not get pale or muted easily.
A printing shop that has this printing method in place with adequate machines can accommodate large orders even in the thousands of t-shirts quantities. This method can be done manually in case the machine breaks down for the process is very straightforward and flexible for you just need flat surfaces to work with.
Disadvantages of Screen Printing Method
Even though the printing process itself is fast, the preparation and setup of the design and the screens demand lots of time and these cost money. The method itself has more steps inherent to it from artwork design all the way to printing if comparisons to other printing methods are made.
You also have to factor in the automatic screen printing machine which is not cheap at all but can save your shop plenty of production time and effort.
This method also uses a lot of inks. It also demands a lot of chemicals and water for cleanup of screens after usage.
DTG Printing Method
This t-shirt printing method is the new kid on the block. There is a degree of familiarity that can be realized by newcomers when first using this. The printing process is very similar to printing documents using one’s laser or inkjet printers only this time a specialized printer is generating the design right on the t-shirt itself.
Fabrics
DTG printing method is similar to its screen printing cousin in the sense that pure or majority-based cotton fabrics work best with it with some exceptions to be discussed later.
I advise that pretreatment is applied on t-shirts to maximize the potential of DTG printing, especially for dark colored garments. This process, also known as pretreat, makes use of a liquid solution used by DTG printers. Printing of white ink on dark colored t-shirts can be handled and there is washability on colored t-shirts especially black ones.
This effectively allows an underbase white ink layer to be printed under the actual design to make the colors that lay on top of that to be more vibrant. The white ink printed remains at the top of the t-shirt and does not get soaked into it.
100% polyester fabrics that have undergone pretreatment can be used with DTG printing method. There are also pretreat t-shirts that can be purchased readily from the apparel market to save you time from doing the process yourself.
Pretreatment can be applied manually or through an automatic pretreat machine.
Drying of pretreat solution can be done through a heat press or simply just airing it out.
Inks
DTG printing method utilizes water-based inks. Prices of these inks have gone down quite a bit due to improved production processes and increased popularity of its usage.
These inks basically fill up every available part of the garments when it is applied to them which makes the final output more delicate and durable.
Beware though of these inks for they produce designs that are quite obscured because of failure to hold on to its base when being cured. High humidity printing environments might make this condition more pronounced since the inks evaporate quite easily.
There is also a chance that the final output might not look the same compared to the original design because these inks are of a semitransparent variety.
Preparation and Printing
DTG printing requires the use of a computer, similar to the screen printing method, to come up with the artwork for the design. It can use any software available that will allow you to work with the image as a whole instead of in layers.
These are critical things to recall when working with DTG artwork on the computer:
- It is required that your monitor is calibrated rightfully so that the colors on the screen are the same as what you have on the file itself. Or, you can have a printed sample color swatch on the same garment color to use as a color guide.
- Do not use effects like faded edges at all!
- The transparent background needs to be in place behind the image.
- Conversion of artwork to pixels is needed.
- It is important that artwork utilizes a resolution of 150 dots per inch (dpi) and saved in TIFF or PDF formats to keep the image quality in place.
- Use the CMYK model when printing. If not, the resulting print will be dull in nature.
It is now time to print your artwork after accomplishing all these steps.
A RIP (Raster Image Processor) software installed in your computer will come in handy, This software allows you to manage printing jobs spread across several printers, control color output, and have other nifty functions. Onyx, Colorburst, and EFI are some of the well-known software of this type.
Put the t-shirt in the DTG printer checking to make sure it is flat and even and select the print option. Using a silicon paper placed in between the t-shirt, dry this garment using a heat press for about ninety seconds.
DTG Printers
These are some of the DTG printers that are available in the market today:
- Col-Desi (DTG Digital) M2
- Freejet 330TX
- Brother GTX
- Kornit Breeze
- Epson F2100
- M&R M-Link-X
Automatic Pretreat Machine
This machine allows for a faster pretreatment solution application to t-shirts. It is an enclosed device where you can load the t-shirt and the machine will take care of applying the solution itself. You can obtain an even coat that can be hard to get with a manual method.
Heat Press
This is a multi-application device that can be channeled for a multitude of purposes. Its purpose is to facilitate permanent heat transfer to a surface. It renders an accurate pressure, temperature, and time in the actual transfer process.
Flatbed and rotary types are available and come in hand-operated, semi-automatic, and fully automatic modes using hydraulic or compressed air systems.
Advantages of DTG Printing Method
Working with DTG printing method allows you to come out with great designs that are very detailed and intricate. For a newcomer, the learning curve is not that steep for as long as one knows how to use a computer, he or she will become an expert in no time at all.
The printing steps are easy to master. By extension, the setup costs are minimal and this could mean greater profitability for the same kind of printing job.
Environmentally, this is a big winner for it does not use a lot of inks. And whatever inks this printing method does utilize is water-based meaning it is relatively safe compared to other inks.
Disadvantages of Screen Printing Method
Even though the printing setup costs are minimal, the initial investment is quite high. The DTG printer is very expensive and unless a shop adds more of its kind, big order volume cannot be handled that easily with this printing method.
Pretreatment is another added cost here. Depending on how deep are the pockets of a printing shop, getting an automatic pretreat machine together with the solution are simply added expenses to the shop.
There is the issue of the maintenance of the printer also. This includes cleaning of wiper blades, ink waste, the capping station, and keeping the print head from clogging.
Sublimation Printing Method
Also known as dye sublimation, printers like myself use this method to get amazing big designs to be spread on the t-shirt in its entirety. It is as if these same designs are integrated with the fabric itself.
Fabrics
This printing method works best with light polyester and polymer-coated fabrics. However, a 85/15 and 50/50 blends of polyester/cotton will also work here. The cotton content gives the t-shirt comfortability in wear and a softer touch.
Predominantly cotton-based fabrics are a big no-no here for the results will be terrible at best.
The print result will be very durable and have a very nice look.
Inks
This printing method uses specialized inks only. These same inks will need to print images with intense colors, sharp contours, vibrant colors. Resistance to perspiration along with increased wash fastness are also selling points of these same inks.
Aqueous type dye sublimation ink is the more famous type which is what is being used on large format and desktop printers. The other one is the solvent type dye sublimation ink primarily utilized in Spectra and certain Konica wide format printers.
It is critical that you use the same brand of dye sublimation printer and ink to prevent complications.
Preparation and Printing
First, you have to do is come up with your design using a computer similar to the DTG and screen printing methods. It differs afterward for you have to print this same design using a sublimation paper and using a specialized sublimation printer.
While the printing process is ongoing, the inks in this printer are deposited to the paper using an electric charge. This same electric charge heats up the ink one color at a time and places them on the sublimation paper. Only once a particular color is finished printing will the sublimation printer carry on to the next color.
A cooling part of the sublimation printing happens to accommodate the switch from to a lighter color from a darker one.
You will also notice that this sublimation printer rolls in and out the paper multiple times in the course of printing.
This process may be repeated from four to five times (in case there is a need for a black thermal transfer process). Laying the colors is done by the first three runs while the last one deposits the laminate on the top.
With the design printed on the sublimation paper, it is now time to transfer the same to your t-shirt.
Check first your t-shirt that it is not wrinkled at all. Then, insert a protective paper in between and use a heat press briefly on it.
Place the printed design on the top part of this t-shirt and cover yet again with another protective paper.
Have the heat press placed on this garment with medium pressure set at 375F for about 50 seconds.
This process will deposit the design on your t-shirt like magic.
Sublimation Printers
These sublimation printers can have up to 64-inch width and can handle printing jobs on soft signage, decor, and merchandising aside from garments. They can have up to 8 modes of colors capability.
These are some of the best dye-sublimation printers around:
- Canon SELPHY CP760 Compact Photo Printer
- Canon SELPHY CP1300 Wireless Compact Printer
- Epson Inkjet C88+
Heat Press
A heat press is a necessary piece of equipment in this t-shirt printing method. A good one can make a big difference here.
You can take your pick among these types of heat press available on the market. This will depend on what you are type or surface you want to handle in your business.
T-shirts, caps, mugs, and shoes – use a small format heat press
Flags, exterior banners, and big signage – use calendar heat press
Aluminum, floor mats, and hardboards – use flatbed heat press
Phones, plates, and trophies – use 3D vacuum heat press
Advantages of Sublimation Printing Method
The sublimation printing method does not demand plenty of time to come up with the design. A simple photograph can be used for this purpose and transferring it to the sublimation paper is quite easy to handle. Also, the actual transfer of this same design to the medium itself is not a complicated process.
This type of printing maximizes the real estate in the garment or material being printed upon since it can handle a larger area compared to others. There is an obvious increase in pricing to accommodate requests such as this.
There is a limitless amount of colors that can also be handled here and there is no issue whatsoever in terms of how long will the design last on the printed medium. The design is part of the medium and this makes a big difference.
Disadvantages of Sublimation Printing Method
There is also an issue of investment costs here. The dye sublimation printer is not cheap and you may be needing more than one of this to handle a big demand. If you are considering using this printing method on things aside from garments, you may also have to invest in a special heat press.
The printing process is quite slow and there may be printer breakdowns if this equipment is not maintained properly or used beyond its recommended hours. Large batches of orders are not practical to accept due to this situation.
On the ecological standpoint, trees will have to be cut in order to serve the demand for paper used here since it is not recyclable.
Transfer Printing Method
This printing method can be simply distilled when a design is printed on a surface not made of textile and then eventually transferred to a different one later. A heat press is mandatory in this process.
There are a few kinds of transfers utilized right now which I will discuss later.
Fabrics
This printing method can work with any material. I mainly use this method on synthetic fibers since plastic is involved in the transfer process.
Types of Transfers
Sublimation is a type of transfer discussed already in this blog post.
CAD-Cut Vinyl
This is used mainly for sports teams t-shirts since it enables easy transfer of names, logos, and numbers.
Plenty of colors and textures are available in vinyl and which can be made of use in the personalization of t-shirts. Take your time in going over the different options here for you simply don’t want to regret this choice later.
I recommend that you think of layering these different pieces to obtain a distinct effect that is truly your own. Doing this enables you to achieve a long-lasting effect that will not easily fade or wash away.
When choosing, consider the specific characteristics of certain vinyl materials:
Allows air circulation – use airflow type heat transfer material
Strong and sturdy – use thermo type film heat transfer material
Thin and soft – use fashion type film heat transfer material
Trendy designs – use flock type heat transfer material
CAD-Cut vinyl transfer works best up to 3 colors only.
Stretch Litho
This is the latest thing. It takes the best that digital and screen printing have to offer and unlike CAD-Cut vinyl, this need not be cut anymore.
This process retains the artwork detail in ways better because it gets printed on paper initially. There is no expansion of print that can happen with other mediums.
Plastisol
There are similarities in this type with the screen printing method. They both share the name of the ink used, respective strengths and weaknesses. However, this transfer type is printed on paper and not on the fabric itself.
This is considered the most popular of all transfer types.
Preparation and Printing
Images selected must use at least 300 dpi to obtain best results and saved in vectors either in AI, PDF, or EPS formats.
The artwork needs to be in real size mode in the final print and there should be no presence of shades and gradients in it.
Using heat transfer paper as the transfer material, print the image at hand.
Proceed then to cut the design from the material manually or by using tools.
Using the heat-press, place the heat transfer paper with the design printed against the fully stretched t-shirt. The design is transferred to the fabric. Remove the transfer paper.
Allow the t-shirt to cool down for at least a day before washing. Turn the shirt inside out when washing and avoid using harsh detergents. Air dry the t-shirt after.
Heat Press
Please refer to the entry on this equipment made under the Sublimation Printing Method.
Cricut Machine
Cricut is the name of the company which makes die-cutting machine used for various projects. Some of their gadgets are used for cutting vinyl and other materials. With this machine, removing unnecessary pieces of vinyl from your design is possible.
Other tools that can also accomplish this work are a knife (x-acto), straight pins, and tweezers.
Advantages of Transfer Printing Method
This printing method is relatively cheaper in terms of startup costs when compared to DTG printing. The customer is not shortchanged here for even with simple equipment, he or she is obtaining high-quality prints of full colors.
Versatility and customization are also positive attributes of this method. When printing shorts of sports teams, I am not limited in terms of players names or placements of the same on the garments. I can even use fluorescent tones here which I’m limited with other methods. This is due to the multiple options coming with the transfer paper.
This method is also excellent in copying designs with minute details.
Also, this method is ideal for small printing shops or startups trying to get their feet wet in the industry. Aside from low investment costs, it does not demand a high skill set right away and reject rates are way lower here compared to others.
Equipment does not demand a lot of space and there is not a lot of need to keep printed stocks in storage in anticipation of demand. Orders can simply be accepted and processed as received.
Disadvantages of Transfer Printing Method
This small printing shop mentioned in the previous paragraph cannot accept large or bulk orders if this method will be solely utilized. It will also be limited by the type of garment used for this method prefers working with polyester ones and fabrics that can tolerate high temperatures.
There is also a big amount of work here for the designs that are to be transferred need to be cut piece by piece.
Related Questions
Which fabric is best for t-shirts?
These are some of the popular fabrics used in t-shirt printing.
- Blended fabrics
- Cotton
- Rayon
- Polyester
- Linen
- End on end weave
- Lycra
What is the most durable fabric?
There are choices here such as cotton and linen furniture fabric although these fabrics have to be woven tightly first. You may also consider canvas and microfiber fabrics since they are used on furniture most often.
What is the difference between screen printing and digital printing?
Digital printing requires a computer to process the artwork that will be printed later on the t-shirt. Screen printing uses a wider base of ink when printing and this results in dazzling and brilliant colors even when printed on a dark-colored garment.
Which fabric is used for screen printing?
Synthetic fibers make up the screen printing mesh of which currently two types are available – polyester and nylon.
