Screen Printing vs. Direct to Film (DTF): Which is Right for Your Project?

It starts with an idea! Like most great ideas, it comes with a level of excitement, a blossoming of creativity and in most cases, a group of individuals throwing around design ideas. When it comes to creating your very own custom merchandise, why wouldn’t you be excited?!  The majority of us, want to be a little bit different, a little out of the box, generic can be boring after all! So, ideas are shared, designs discussed, mood boards created, and products reviewed. What colour shirt will be best, what shape of tee suits the majority of the wearers, is a boxy fit or a slim fit modern shape better? Thoughts are bantered around, but finally a style and colour are chosen. The design has come together, print positions are selected and everyone is in agreeance, you have an image of what the custom merch will look like. Now to make it happen!

When everything seems sorted and smiles abound, one final decision needs to be made and suddenly confusion reigns. What is it you ask, that causes frowns to form and indecision amongst the group? It seems simple, but often creates a level of uncertainty, the final big decision – Should we choose Screen Printing or Direct to Film, to make our custom merch come alive?!

Screen printing vs direct to film, how to choose?

Both print methods, screen printing and direct to film (otherwise known as heat transfer) are two of the most prevalent techniques when creating quality custom merchandise. When choosing which print method is best for your project, you want to make an informed decision, as you obviously want the end result to look fabulous!

Screen printing and direct to film (DTF) both have their advantages and drawbacks, depending on the particular requirements and preferences of your project. By understanding their unique characteristics, you can figure out which one is right for you and your creative vision!

Screen Printing: A Century-Old Craft

Screen printing is a tried and tested, robust technique that has been around for over a century. However, it was not until Andy Warhol began popularising the practice in the 1960s that screen printing (or silk screening as it is also known) really started being used in the mainstream.

It is more labour intensive, as separate screens need to be created for each colour of a design. After the design is separated into its individual layers (or colours), the screens are coated with an emulsion. Through exposure to UV light the emulsion hardens in the shape of the design. The areas where colour needs to pass through remain open, and the remainder of the mesh screen is blocked off. Once screens are mounted on the screen-printing press, a squeegee is used to press the ink through the mesh screens directly onto the garment.

The ink then needs to dry (or cure), so a heat source is used between each colour being put down. The curing process ensures the colours are vibrant and long lasting. This printing and drying process is then repeated for each colour in the design.

Benefits of Screen Printing

• Vibrant, bold colours that will make your custom merch pop!
• As the ink becomes part of the fabric, the garment has a softer hand feel.
• Most cost-effective print method for bulk orders with the same design.
• PMS colour matching.
• Reliable and robust results, screen printed apparel will withstand repeated washing and wear well for longer.

Direct to Film: Modern Flexibility

Direct to Film (DTF) is a contemporary and versatile printing approach, which has become more popular in the last 2 decades and certainly has improved from the iron on transfers that were so popular in the 90s! It uses a combination of heat and pressure to transfer a design from specially prepared transfer paper onto the chosen merchandise.

The first step is to print the design onto the transfer paper, followed by covering the back of the print with an adhesive powder. This paper is then placed on the product in the correct position and with the aid of the heat press machine, the design transfers on to the surface of the garment. Basically, heat activates the ink on the transfer paper, causing it to adhere to the fabric’s fibres, sitting on top of the fabric itself. After the item is cooled for a set amount of time, the transfer paper is carefully peeled off and one final press occurs to ensure the design’s durability.

Benefits of Direct to Film

• Great for complex coloured design runs and unique position printing.
• More freedom with colour options and crisp image results.
• Smaller quantities can be managed with ease.
• More flexible in terms of the different fabrics and products you can print on.
• Affordable set up costs.

Making the Right Choice for Your Project

Now that you understand the technique and benefits of both print methods, it ultimately comes down to the unique needs of your project. A more confident choice can be made once you look at the individual factors affecting your project. For example, the size of the run, the type and fabrication of the chosen garment or product, the positioning of the print and of course, the design itself.

If you have a small quantity run, with a complex design with multiple print positions, direct to film (DTF) is a great choice.

However, if you are needing a larger order with the same design and bold colours, screen printing may be the best option, not only based on budget, but also longevity.

Conclusion

Whichever technique you decide on, whether screen printing or direct to film, rest assured, both will produce fantastic results, exceeding your expectations! And with help from our knowledgeable team at QTCo, your original custom merch dreams can be brought to life, giving your designs and your vision the wow factor it deserves.

Frequently Asked Questions