Screen Printing vs DTG vs Sublimation: How T-Shirts Are Made

Angry Chimp

You've seen the tags on graphic tees: "screen printed," "DTG," "sublimation." But what do they actually mean — and why should you care?

Here's the short answer: the printing method determines how your shirt looks, how long the design lasts, and how the fabric feels against your skin. Pick the wrong method for the wrong material, and you end up with cracked graphics after three washes. Pick the right one, and that tee holds up for years.

We're breaking down all three methods — no jargon, no fluff. Just what you need to know before you buy your next graphic tee.

Screen Printing: The OG Method

Screen printing has been around since the 1960s in the commercial t-shirt world, and it's still the most widely used method for bulk orders. It works by pushing ink through a mesh screen (one screen per color) directly onto the fabric.

How It Works

A stencil of your design is created on a fine mesh screen. Ink gets pushed through with a squeegee, one color at a time. Each color requires its own screen, so a 4-color design means 4 separate passes.

Pros

  • Bold, vibrant colors — screen printing lays down thick ink that pops, especially on dark fabrics
  • Extremely durable — properly cured screen prints can outlast the shirt itself
  • Cost-effective at scale — the more shirts you print, the cheaper each one gets
  • Works on almost any fabric — cotton, polyester, blends — screen printing handles them all

Cons

  • Limited detail — photographic images and complex gradients are difficult to reproduce
  • Setup costs — each screen costs money to create, making small runs expensive
  • Color limits — each color adds cost and complexity. Most screen prints max out at 6-8 colors
  • Slight texture — you can feel the ink on the fabric, which some people don't love

Best for: Simple, bold designs with limited colors. Big batch orders. Brands that want that classic, heavy-ink streetwear look.

DTG (Direct-to-Garment): The Detail King

DTG printing works like a giant inkjet printer — for t-shirts. The machine sprays water-based ink directly into the fibers of the fabric, producing photo-quality prints with unlimited colors.

This is the method we use for products like the Angry Chimp Classic Graphic Tee and the No Monkey Business Hoodie. It's how we get the detailed Angry Chimp graphic to look sharp on every piece.

How It Works

The garment gets pre-treated with a solution that helps the ink bond to the fibers. Then it's loaded into a DTG printer, which sprays CMYK ink (plus white for dark fabrics) directly onto the shirt. After printing, the garment gets heat-pressed to cure the ink.

Pros

  • Unlimited colors — full-color, photographic designs with smooth gradients
  • Incredible detail — fine lines, small text, and complex artwork reproduce perfectly
  • Soft hand feel — the ink absorbs into the fabric rather than sitting on top. You feel the shirt, not the print
  • No minimum order — print one shirt or a thousand. No setup screens needed
  • Eco-friendlier — water-based inks and less waste than screen printing

Cons

  • Slower production — each shirt is printed individually, so it's not as fast as screen printing for large orders
  • Works best on cotton — DTG ink bonds best to natural fibers. 100% cotton or cotton-dominant blends give the best results
  • Requires pre-treatment for dark garments — adds time and can slightly affect fabric feel if not done properly
  • Cost per unit stays flat — unlike screen printing, the price doesn't drop much with larger quantities

Best for: Detailed, multi-color designs. Small to medium runs. Cotton garments. Brands that prioritize print quality and fabric feel.

Sublimation: The All-Over Print Specialist

Sublimation is a heat-transfer process that turns ink into gas and permanently bonds it to synthetic fibers. The result is a print that becomes part of the fabric — it won't crack, peel, or fade because the ink is literally inside the material.

Our Angry Chimp Compression Tee uses sublimation-compatible synthetic fabric (90% polyester, 10% spandex) to achieve vibrant, durable prints that hold up through intense training sessions.

How It Works

The design is printed onto special transfer paper using sublimation ink. The paper is placed on the garment and pressed with high heat (around 400°F). The heat causes the ink to convert from solid to gas, which penetrates the polyester fibers and permanently bonds at the molecular level. When it cools, the ink re-solidifies inside the fabric.

Pros

  • Zero texture — the print is literally inside the fabric. No cracking, peeling, or raised edges. Ever.
  • All-over printing — you can print seam to seam, covering the entire garment
  • Extreme durability — the design won't wash out because the dye is embedded in the fibers
  • Vibrant colors on light fabrics — brilliant, full-spectrum color reproduction
  • Performance-ready — since nothing sits on top of the fabric, it won't affect moisture-wicking or stretch

Cons

  • Polyester only — sublimation doesn't work on cotton. The fabric must be synthetic or have a high polyester content
  • Light garments only — sublimation ink is translucent, so it won't show up on dark fabrics
  • Can't add to existing garments — the shirt is usually printed on white fabric first, then cut and sewn
  • Higher base cost — the cut-and-sew process is more complex than printing on a pre-made blank

Best for: Athletic and performance wear. All-over prints. Polyester garments. Designs that need to withstand heavy washing and intense activity.

Side-by-Side Comparison

Feature Screen Printing DTG Sublimation
Best Fabric Any (cotton preferred) 100% cotton Polyester only
Color Range Limited (6-8 per design) Unlimited Unlimited
Detail Level Good Excellent Excellent
Hand Feel Raised/textured Soft (ink in fibers) Zero (part of fabric)
Durability High High (with proper care) Highest
Print Area Front/back/sleeve Front/back/sleeve All-over (seam to seam)
Dark Garments Yes Yes (with pre-treatment) No
Eco Impact Higher (plastisol inks) Lower (water-based) Moderate
Min Order 12-24 units typical 1 unit 1 unit
Cost Per Unit Low at scale, high for singles Flat rate Higher (cut-and-sew)

Which Method Is Best for You?

There's no single "best" method — it depends on the garment and the design.

If you're buying a cotton graphic tee with detailed artwork, look for DTG. The print quality is unmatched on cotton, and the soft hand feel means you're wearing a shirt — not a sticker. That's why we chose DTG for our graphic tees collection.

If you're buying performance wear — compression shirts, athletic gear, anything polyester — sublimation is the move. The print becomes part of the fabric, so it won't crack during workouts or peel in the wash.

If you're buying in bulk with a simple, bold design, screen printing is hard to beat on cost and vibrancy.

How to Make Your Prints Last

No matter the printing method, proper care extends the life of your graphic tees. The short version: wash inside out, cold water, hang dry. For the full breakdown, check out our complete guide to washing graphic tees without fading.

FAQ

Is DTG or screen printing better for graphic tees?

DTG is better for detailed, multi-color designs on cotton. Screen printing is better for bold, limited-color designs at high volume. For everyday graphic tees with complex artwork, DTG gives a softer feel and sharper detail.

How long do DTG prints last?

DTG prints last 50+ washes when properly cared for. Wash inside out in cold water and avoid high-heat drying. The ink bonds directly to cotton fibers, so it fades gradually rather than cracking or peeling like some screen prints.

Can you sublimate on cotton t-shirts?

No. Sublimation only works on polyester or polyester-coated materials. The ink needs synthetic fibers to bond with at the molecular level. On cotton, sublimation ink will wash out almost immediately.

Which printing method is most eco-friendly?

DTG is generally the most eco-friendly option. It uses water-based inks, produces minimal waste (no screens or excess ink), and doesn't require harsh chemicals like some screen printing plastisol inks.

Why do some graphic tees crack and peel?

Cracking usually happens with screen-printed plastisol ink that wasn't properly cured, or when heat-transfer vinyl breaks down over time. DTG and sublimation prints don't crack because the ink is absorbed into the fibers rather than sitting on top of them.

Your Move

Now you know what's behind the print on your favorite graphic tees. Want to see quality DTG and sublimation printing in action? Browse the full Angry Chimp collection — every piece is printed to last.

Read next:

Read Next

Back to blog