What Is Direct-to-Garment Printing? (And Why It's Better)

You've probably noticed: some graphic tees feel amazing, with prints that stay vibrant wash after wash. Others feel stiff, crack after a few washes, and look faded within months.

What's the difference? Usually, it's the printing method.

Most people have no idea how their shirts are made. They just know some feel better than others. And that's fair—why would you need to know the technical details of garment printing?

Here's why it matters: understanding the difference between printing methods helps you spot quality before you buy. It explains why some $10 shirts fall apart while $25 shirts last for years. And it helps you make smarter purchasing decisions.

Today, we're breaking down Direct-to-Garment (DTG) printing—what it is, how it works, and why it's the premium printing method that Lucky Spark (and other quality brands) use.

By the end of this post, you'll be able to spot DTG printing, understand why it costs more, and know exactly what you're paying for when you invest in a quality graphic tee.

The Three Main Printing Methods (The Quick Overview)

Before we dive deep into DTG, let's establish what you're comparing it to.

1. Screen Printing

How it works: Ink is pushed through a mesh screen onto the fabric. Each color requires a separate screen.

Best for: Large bulk orders (100+ shirts), simple designs with few colors

Pros:

Cheapest for bulk production
Durable (when done right)
Vibrant colors

Cons:

Setup costs make small orders expensive
Limited detail/complexity
Can crack and peel over time
Feels thick and plasticky on the shirt

2. Heat Transfer/Vinyl

How it works: Design is printed on transfer paper or cut from vinyl, then heat-pressed onto the shirt.

Best for: One-off custom shirts, names/numbers on sports jerseys

Pros:

Quick and easy
No setup costs
Works for single shirts

Cons:

Very prone to cracking and peeling
Stiff, uncomfortable feel
Poor durability
Doesn't age well at all

3. Direct-to-Garment (DTG)

How it works: Specialized inkjet printer prints the design directly into the fabric fibers.

Best for: Complex designs, multiple colors, small to medium runs, premium quality

Pros:

Incredible detail and color accuracy
Soft to the touch (no raised plastic feel)
Durable (when cared for properly)
No minimum order quantities
Environmentally friendlier

Cons:

More expensive per shirt
Works best on 100% cotton or cotton blends
Requires proper garment care

The verdict: DTG is the premium option. It costs more, but the quality difference is immediately noticeable.

How DTG Printing Actually Works

Let's get into the details of what makes DTG special.

Step 1: Pre-Treatment

Before printing, the shirt is sprayed with a pre-treatment solution. This helps the ink bond properly with the fabric fibers.

Why it matters: This step is what allows the ink to penetrate the fabric instead of sitting on top like screen printing.

Step 2: Printing

The shirt is loaded onto the printer (similar to loading paper into a regular printer, but much more precise). The specialized printer then prints the design directly onto the fabric using water-based inks.

What makes it special:

Prints in CMYK + white (allows for full-color designs)
Incredibly high resolution (photo-quality detail)
Prints directly into fabric fibers (not on top)

The difference: With screen printing, you can feel the ink sitting on top of the fabric. With DTG, the ink becomes part of the fabric. Run your hand over a DTG print, and it feels smooth.

Step 3: Curing

After printing, the shirt goes through a heat press or conveyor dryer to cure (set) the ink. This bonds the ink permanently to the fabric.

Why it matters: Proper curing is what makes DTG prints durable. Undercured prints will wash out quickly.

Step 4: Quality Check

Good DTG printers inspect every shirt for:

Color accuracy
Print clarity
Proper coverage
Any defects or misprints

Why it matters: Quality control ensures you're getting a product that meets standards. Cheap DTG operations skip this step.

DTG vs. Screen Printing: The Real Differences

Let's compare the two most common methods side by side.

Feel and Comfort

Screen Printing:

Raised, plasticky texture
Can feel stiff and uncomfortable
Creates a "layer" on top of fabric
Gets stiffer over time

DTG Printing:

Soft, barely noticeable
Feels like part of the fabric
No raised texture
Stays soft wash after wash

Winner: DTG (by a landslide)

Durability

Screen Printing:

Can crack and peel with wear
Fades over time
Cracking gets worse with each wash
Lifespan: 25-50 washes (depending on quality)

DTG Printing:

Won't crack or peel (ink is IN the fabric)
Colors stay vibrant longer
Graceful aging (fades subtly, like vintage shirts)
Lifespan: 50+ washes (with proper care)

Winner: DTG (when cared for properly)

Detail and Complexity

Screen Printing:

Limited to simple designs
Each color = separate screen = higher cost
Hard to do gradients or photo-realistic images
Best for bold, simple graphics

DTG Printing:

Unlimited colors (no extra cost)
Photo-realistic detail possible
Gradients, shading, complex artwork—all achievable
Perfect for intricate designs

Winner: DTG (no contest)

Cost

Screen Printing:

Cheap per shirt (for large orders)
High setup costs (screen creation)
Not economical for small orders
Best pricing at 100+ units

DTG Printing:

Higher per-shirt cost
No setup fees
Economical for small runs
Same price whether you print 1 or 100

Winner: Depends on order size

Small orders (1-50): DTG
Large orders (100+): Screen printing

Environmental Impact

Screen Printing:

Uses plastisol inks (petroleum-based)
Requires harsh chemicals for screen cleaning
More waste (excess ink, screens, chemicals)

DTG Printing:

Uses water-based, eco-friendly inks
Minimal waste (prints exactly what's needed)
Less chemical usage
More sustainable overall

Winner: DTG

Why Lucky Spark Uses DTG Printing

At Lucky Spark, we chose DTG printing for very specific reasons. It wasn't the cheapest option, but it was the right one.

1. We Prioritize Quality Over Profit Margins

We could use cheaper printing methods and save money. But that would mean:

Stiffer, less comfortable shirts
Designs that crack and peel
Customers who don't come back

DTG costs more upfront, but it delivers the quality we're proud to put our name on.

2. Our Designs Deserve Better

We spend hours perfecting designs. Our graphics are detailed, our text is carefully chosen, and our layouts are thoughtfully composed.

Printing them with cheap methods would be like framing a masterpiece in a cardboard frame. The medium matters.

3. We Want Shirts You'll Wear for Years

Throwaway fashion is wasteful. We want you to wear your Lucky Spark shirt for years, not months.

DTG printing, combined with premium cotton, creates shirts that become favorites in your wardrobe—the ones you reach for again and again.

4. Small Batch Flexibility

DTG allows us to:

Release new designs without huge minimums
Test designs before committing to large runs
Offer more variety
Respond quickly to customer feedback

This flexibility lets us stay creative and responsive rather than being locked into rigid production schedules.

How to Spot DTG Printing (Before You Buy)

Shopping online? Here's how to tell if a shirt is DTG printed:

✓ Look for These Clues:

"Direct-to-Garment" or "DTG" mentioned in description
If they're using it, they'll probably brag about it.

Soft-hand or soft-feel printing mentioned
This is DTG language.

Complex, detailed designs
If the design has lots of colors, gradients, or photo-realistic elements, it's probably DTG.

Higher price point
DTG shirts typically cost $20-$35. Cheaper shirts are probably screen printed.

Premium cotton fabric mentioned
DTG works best on quality cotton. If they're advertising DTG, they'll mention the fabric too.

✗ Red Flags (Probably NOT DTG):

Very cheap pricing ($10 or less)
DTG is expensive to produce. Rock-bottom prices usually mean screen printing or heat transfer.

Bulk discount pricing
"Buy 10, get them for $8 each!" suggests screen printing (which gets cheaper at volume).

Limited color options
If designs only come in 2-3 colors, they're probably screen printed (color limitations).

No fabric details mentioned
Cheap operations don't bother explaining their process or materials.

Caring for Your DTG Printed Shirts

DTG prints are durable, but they last even longer with proper care.

Do This:

✓ Turn inside out before washing
Protects the print from friction

✓ Wash in cold water
Heat breaks down inks faster

✓ Use gentle detergent
Harsh chemicals fade prints

✓ Air dry or tumble dry low
High heat damages inks

✓ Avoid fabric softener
Creates a coating that degrades prints

Don't Do This:

✗ Wash in hot water
Causes fading and degradation

✗ High heat drying
Breaks down ink bonds

✗ Iron directly on the print
Can melt or damage the ink

✗ Bleach
Destroys colors and prints

Follow these rules, and your DTG shirt will look great for 50+ washes.

The Cost Question: Why DTG Shirts Cost More

Let's address the elephant in the room: DTG shirts ARE more expensive. Here's why that's justified.

Higher Production Costs

Specialized equipment (DTG printers cost $15,000-$100,000+)
Pre-treatment chemicals
Premium water-based inks
Quality cotton garments (DTG works best on good fabric)
Skilled operators

The math: A DTG printer might produce 30-50 shirts per day. A screen printing operation can produce 500+. Lower volume = higher per-shirt cost.

Quality Materials

DTG requires:

Better fabric (100% cotton or premium blends)
Higher-quality blank shirts
Premium inks

Cheap shirts and cheap inks produce cheap results. Quality inputs = quality outputs.

What You're Actually Paying For

When you buy a DTG shirt, you're paying for:

Superior comfort and feel
Durability that lasts years
Designs that won't crack or peel
Environmental responsibility
Supporting small businesses who prioritize quality

The value equation: A $25 DTG shirt that lasts 3 years = $8.33/year. A $10 screen-printed shirt that lasts 6 months = $20/year.

DTG is actually cheaper in the long run.

Common DTG Myths (Debunked)

Let's clear up some misconceptions.

Myth #1: "DTG Prints Fade Faster Than Screen Prints"

Reality: Properly cured DTG prints are just as durable as screen prints. The difference is care—DTG requires gentle washing (but so should screen prints if you want them to last).

Myth #2: "DTG Only Works on White Shirts"

Reality: DTG works beautifully on dark shirts. The printer lays down a white under-base layer first, then prints the colors on top. It takes longer and costs more, but it works great.

Myth #3: "DTG Is Just Fancy Iron-On Transfers"

Reality: Not even close. Heat transfers sit ON the fabric. DTG inks penetrate INTO the fabric. Completely different processes, completely different results.

Myth #4: "Screen Printing Is Always Better"

Reality: Screen printing has its place (bulk orders, simple designs), but DTG is superior for detail, comfort, and small-to-medium runs. Neither is universally "better"—they're different tools for different jobs.

The Future of Garment Printing

DTG technology keeps improving. What's on the horizon?

Faster Production Speeds

New printers are getting faster while maintaining quality. This will eventually bring costs down.

Better Ink Technology

Water-based inks are becoming more durable and vibrant. Future inks will last even longer.

Expanded Fabric Compatibility

Currently, DTG works best on cotton. New inks and pre-treatments are expanding to polyester blends and other fabrics.

More Sustainable Options

Eco-friendly inks, lower energy consumption, and waste reduction are priorities for the industry.

The trend: DTG is becoming the standard for quality custom apparel. As technology improves and scales, expect to see it everywhere.

The Bottom Line: DTG Is Worth It

If you care about:

Comfort (soft shirts that feel great)
Durability (lasting years, not months)
Design quality (detailed, vibrant graphics)
Sustainability (eco-friendly production)

Then DTG printing is what you want.

Yes, it costs more upfront. But you're paying for quality that lasts. You're investing in shirts you'll actually wear, not throwaway fashion that falls apart.

At Lucky Spark, we believe quality matters. That's why every shirt we make uses DTG printing on premium cotton. We'd rather make fewer sales at a fair price than compromise on quality.

Your wardrobe deserves better than cheap shirts that disappoint. And you deserve to know what you're buying.

Ready to experience the DTG difference?

👉 Shop All Lucky Spark Shirts - Premium DTG quality
👉 Musician Collection - For players who appreciate quality
👉 Mechanic Collection - Built to last
👉 Funny Collection - Humor that doesn't fade

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Questions about DTG printing? Drop them in the comments!

December 31 2025 0 Comments Rune Holth