Introduction

For startups, independent brands, and small print shops, choosing between DTF (Direct-to-Film) and screen printing can make or break margins—especially at small quantities. This article delivers a data-driven comparison using realistic assumptions and recalculated tables, including one-off production scenarios.

Assumptions used in this analysis:

• Blank shirt: $5.00 each
• DTF consumables for a 4×5 cm logo: $0.01
• DTF setup cost: $0
• DTF labor: $0.50 per shirt
• Screen printing: 5-color design, setup $25/color → $125 total
• Screen printing ink: $0.30 per shirt
• Screen printing labor: $0.70 per shirt
• Overheads, shipping, and taxes excluded to focus on production costs

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Technology Overview

DTF Printing

Direct-to-Film (DTF) prints designs onto film and transfers them to fabric with heat and adhesive powder.

• Strengths: Minimal setup, ideal for small runs and complex, multi-color graphics.
• Limitations: Per-shirt labor can add up compared to automated screen printing.

Screen Printing

Screen printing uses stencils (screens) to transfer ink through mesh.

• Strengths: Highly durable, very cost-effective in bulk, industry standard.
• Limitations: High setup cost per color makes it inefficient for very small batches.

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Cost Model

DTF (per shirt)

DTF cost/shirt=$5.00 (blank)+$0.01 (consumables)+$0.50 (labor)=$5.51

Flat cost per shirt, regardless of volume.

Screen Printing (5-color job)

Screen cost/shirt at quantity N=(N$125 setup​)+$5.00 (blank)+$0.30 (ink)+$0.70 (labor)=(N125​)+$6.00

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One-Piece Production Cost

• DTF (1 shirt): $5.51
• Screen printing (1 shirt): $131.00 (setup + variable costs)

This shows why DTF is the preferred method for one-off and on-demand printing.

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Scenario: 50 Multi-Color T-Shirts

DTF — 50 units

• Per shirt: $5.51
• Total: $275.50

Screen Printing — 50 units

• Per shirt: $8.50 (setup $125 ÷ 50 + $6.00)
• Total: $425.00

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Cost Comparison by Quantity

Per-shirt cost

Quantity (N)	DTF	Screen Printing (5-color)
1	$5.51	$131.00
10	$5.51	$18.50
50	$5.51	$8.50
100	$5.51	$7.25

Order total

Quantity (N)	DTF Total	Screen Printing Total (5-color)
1	$5.51	$131.00
10	$55.10	$185.00
50	$275.50	$425.00
100	$551.00	$725.00

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Insights

• DTF provides a flat, predictable cost of $5.51 per shirt at any order size in this case.
• Screen printing costs decline with larger volumes, but remain higher than DTF with these assumptions.
• To make screen printing cheaper, the design would need fewer colors, larger batch sizes, or lower labor/ink costs.

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Beyond Cost: Strategic Factors

• Design complexity: DTF handles unlimited colors and gradients at no extra cost; each screen color increases cost.
• Turnaround time: DTF is immediate; screen printing requires time for screen preparation.
• Durability & feel: Screen prints often feel softer and last long; DTF has a slightly heavier hand feel but remains durable.
• Business risk: DTF enables true on-demand production with low inventory risk. Screen printing works best for predictable bulk runs.

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Decision Framework

• Single shirts or <50 units: DTF is the clear choice.
• 50–100 units with complex designs: DTF remains cost-effective.
• 100+ units, simpler designs (1–2 colors): Screen printing becomes competitive.
• Need samples or fast turnaround: Always DTF.

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Conclusion

In comparing DTF vs. screen printing cost for small-batch and on-demand production:

• DTF printing offers stable, low cost at $5.51 per shirt, ideal for one-offs, prototypes, and small runs.
• Screen printing is more expensive at small volumes but improves as orders scale, especially with fewer colors.

Takeaway:

• Entrepreneurs and small studios should choose DTF for flexibility and predictable costs.
• Established businesses with bulk orders should leverage screen printing when scale and simplicity make it more cost-efficient.

Disclaimer: Prices reflect 2024 industry averages. Actual results vary by supplier, labor rates, automation, and artwork complexity.