Understanding the 4 Different Shirt-Making Processes: Sublimation, DTF, Puff Vinyl & Screen Printing
If you’ve ever ordered custom shirts, you already know there are lots of ways to bring a design to life. Each method has its own strengths, style, and ideal use. Whether you’re creating team shirts, spirit wear, small-batch gifts, or merch for your business, choosing the right printing process will help your design look its best and stay budget-friendly.
Here’s a simple breakdown of the four most popular shirt-making processes we offer—and when to use each one!
1. Sublimation Printing
Sublimation is perfect for bright, vibrant, long-lasting prints. The design is printed with special ink and then heat-pressed into the fabric, permanently bonding with the fibers.
Best for:
Light-colored polyester shirts (it won’t work on cotton)
Full-color photos, detailed artwork, or multicolored designs
A soft, no-feel finish (the design becomes part of the shirt!)
Why choose it:
Sublimation never cracks or peels and is ideal for single orders or small batches because there’s no minimum quantity.
Limitations: Shirts must have a high poly count, and light-colored shirts will not show up on dark-colored shirts. There is no white ink in sublimation printing.
2. DTF (Direct-to-Film) Transfers
DTF has become extremely popular because of its crisp detail and versatility. Designs are printed on a film, powdered, cured, and then heat-pressed onto almost any fabric.
Best for:
Cotton, polyester, blends, fleece—almost everything!
Small or large orders
Designs with gradients, lots of color, or fine detail
Why choose it:
DTF lays on top of the fabric, giving a flexible, durable, slightly raised feel. It’s perfect for one-off shirts or short runs without setup fees.
Limitations: Large full color graphics can wrinkle, crack, or peel over time; best for text designs or designs that do not cover a large majority of the shirt.
3. Puff Vinyl
Puff vinyl is applied like regular heat-transfer vinyl—but when heat-pressed, it expands, giving the design a fun, dimensional, lifted look.
Best for:
Bold words, block letters, or simple designs
Spirit wear, trendy designs, kids shirts, and boutique-style apparel
Small quantities or single shirts
Why choose it:
It gives that cool, textured finish that stands out without needing a large order. Great for names, mascots, seasonal phrases, and script fonts.
Limitations: One-color designs work best. Puff vinyl will not layer on top of itself, it can be layered with a flat vinyl on the bottom like a glitter for an extra pop
4. Screen Printing
Screen printing is the classic method used for large batches. Each color is pushed through a fine mesh screen onto the shirt, creating bold, durable designs that last wash after wash.
Best for:
Team shirts
School events
Large groups
Company shirts
Designs with 1–4 solid colors
IMPORTANT: Minimum Order of 30 Shirts
Because screen printing requires burning screens, setup, and cleanup for each color, we require a minimum order of 30 shirts.
If you need fewer than 30, one of the other methods—DTF, Sublimation, or Puff Vinyl—will be used instead.
Why choose it:
It’s cost-effective for big orders, extremely durable, and provides smooth, professional results.
Limitations: 4 Color artwork can not be used; individual colors are used instead. The prices are based on the number of colors in your artwork. So the more colors in your design, the more expensive the shirt.
Which Process Should You Choose?
Here’s a quick cheat sheet:
1–29 shirts: Sublimation, DTF, or Puff Vinyl
30+ shirts: Screen printing (best value!)
Bright/detail-heavy designs: DTF or Sublimation
Texture & trendiness: Puff Vinyl
Long-lasting group shirts: Screen printing
No matter which method you choose, each printing process has its own charm and purpose—and we’re here to help you pick the right one for your project!
If you want help choosing the best process for your next order, feel free to reach out!