DTG vs. Screen Printing: Which is Right for Your Bulk Order?
- Paolo Livelo
- Apr 5
- 5 min read
Choosing the right way to print your gear is the difference between a "wow" and a "whatever."
You have a big event coming up. Maybe it’s a corporate launch in Brisbane, a gym opening in Moreton Bay, or a new merch drop for your brand in South Western Sydney. You need bulk custom t shirts Australia-wide, and you need them to look sharp.
But then you hit a wall. Should you go with Direct to Garment (DTG) or Screen Printing?
Don't panic. We are here to make this easy. At So Boss, we live and breathe clothing printing services. We know exactly which method will save you money and which one will make your logo pop.
Pick. Print. Profit.
What is Direct to Garment (DTG) Printing?
Think of DTG as a giant, high-tech inkjet printer for your clothes.
Instead of paper, we load a high-quality AS Colour tee. The printer sprays the ink directly into the fabric fibers. It’s fast to set up. It’s incredibly detailed. It’s perfect for those designs that have more colors than a rainbow.
Why Choose DTG?
Zero Setup Fees: Since there are no screens to make, we can start printing immediately.
Detail is King: If your design is a high-resolution photo or a complex illustration (like our Dad Collage Tee), DTG is the only way to go.
Soft Feel: The ink soaks in, so you don’t get that "heavy plastic" feel on your chest.
Small Batches: If you only need ten shirts, DTG is your best friend.
Is it perfect for everything? No. For massive bulk orders of 500+ shirts with a simple one-color logo, the per-unit cost stays relatively flat. You don't get those "bulk buy" discounts that come with traditional methods.
What is Screen Printing?
Screen printing is the traditional heavy hitter.
We create a physical stencil (the screen) for every color in your design. We then push thick, durable ink through that screen onto the garment. It’s a process that takes time to set up, but once we start, we can move like lightning.
Why Choose Screen Printing?
Bulk Savings: This is where you save the big bucks. The more you order, the cheaper each shirt becomes.
Vibrancy: The ink sits on top of the fabric. It is bold. It is bright. It stands out from a mile away.
Toughness: Screen-printed shirts are built for the long haul. They handle the wash like a champ.
Color Matching: Need an exact Pantone shade for your corporate brand? Screen printing is the answer.
Wait. There is a catch. Screen printing has "setup costs" because we have to burn those physical screens. If you have a 10-color logo and only want 20 shirts, the setup fee will hurt your wallet. Save this for your big clothing printing services runs.
The Cost Comparison: Which Saves You More?
Let's talk numbers. You want the best bang for your buck.
The Small Batch (1–20 units)
For small runs, DTG is the undisputed winner. You aren't paying for screens, so your "price per shirt" starts lower. If you’re just grabbing a few The Legend Tees for a weekend event, go digital.
The Medium Run (20–50 units)
This is the "grey area." If your design is simple (one or two colors), screen printing might start to pull ahead. If your design is a full-color masterpiece, stick with DTG. (We can help you decide which path is cheaper during the quote process).
The Bulk Order (50+ units)
Screen printing wins. Period. Once the screens are made, the labor cost per shirt drops significantly. If you are ordering for a whole company or a massive sporting club, this is the most economical way to get bulk custom t shirts Australia has to offer.
Quality and Durability: Which Lasts Longer?
You don't want your shirts peeling after three washes. (We don't either).
Screen printing is famous for its durability. The ink is thicker and "cured" under high heat. It is perfect for workwear or uniforms that get a lot of abuse.
DTG has come a long way. Modern DTG inks are high-quality and long-lasting, but they will naturally fade a little faster than screen printing over 50+ washes. It gives the shirt a "vintage" feel that many people actually prefer.
Which do you need? Hard work? Screen print. Fashion merch? DTG.
Local Legend Status: Brisbane, Moreton Bay, and Sydney
We aren't just a website. We are your local partners.
Whether you are in the heart of Brisbane, out in Moreton Bay, or over in South Western Sydney, we understand the local market.
Brisbane Tradies: You need tough, screen-printed hi-vis or cotton tees that can handle the humidity and the hard work.
Sydney Brands: You need high-end DTG prints on premium AS Colour blanks to compete in the fashion scene.
Moreton Bay Events: You need the right turnaround for the job. DTG is the speed king for urgent runs, while screen printing and DTF are better suited to planned bulk orders.
We ship everywhere, and we do it fast. DTG orders placed by 10am can qualify for same day print and dispatch. Screen printing and DTF sit in our full range service window of 5–14 business days plus shipping. You can check our shipping policy here to see how we get your bulk orders to your door.
The "Boss" FAQ: Everything You Need to Know
Q: How do I prep my files for a bulk order? A: High resolution is everything. Send us your files in 300 DPI (dots per inch) or as a vector file (.AI or .EPS). If your art is blurry, your shirt will be blurry.
Q: Can I mix shirt sizes in one bulk order? A: Yes! You can mix Small, Medium, XL, and 3XL in the same run. As long as the print design stays the same size, the price remains consistent.
Q: What is your guarantee? A: We stand by our work. If we mess up the print or the shirt is faulty, we fix it. Check our guarantee page for the full breakdown.
Q: Does screen printing work on hoodies? A: Absolutely. Screen printing on heavy fabric like hoodies and jumpers is a great way to get a premium look for your winter merch.
Q: What is the fastest turnaround time? A: DTG is the speed king. If you order by 10am, DTG can qualify for same day print and dispatch. Screen printing and DTF are part of our full range service, which is typically 5–14 business days plus shipping (best for bulk precision, planning, and larger runs).
The Verdict: Which One Should You Pick?
Still stuck? Let's simplify it.
Choose DTG if:
You have a photo or 5+ colors in your art.
You need less than 20-30 shirts.
You want the softest feel possible.
You need same day dispatch (order by 10am).
Choose Screen Printing if:
You are ordering 50+ shirts.
You have a simple 1–3 color design.
You need extreme durability for workwear.
You want the lowest price per unit.
You are planning for our full range turnaround of 5–14 business days plus shipping.
Choose DTF if:
You want sharp, consistent results across a wider garment range.
You need flexible bulk decoration without a same-day claim.
You are planning for our full range turnaround of 5–14 business days plus shipping.
You want bulk precision over rush speed.
Ready to Start Your Order?
Don't let the technical stuff slow you down. Whether you need a single Best Dad Ever Blue Tee or a thousand custom shirts for your new startup, we’ve got your back.
Order. Print. Done.
Click over to our shop and let’s get your project moving. If you're still not sure which method fits your budget, just reach out. We’ll help you make the "Boss" choice.
Quick Links for Your Peace of Mind:
Don't settle for average. Be the Boss.
Comments