How to Choose the Best Printing Method for Your Apparel (And Avoid Costly Mistakes Most People Make)
- Carol Womack
- Mar 21
- 3 min read
Updated: Mar 23
Which is the Best Printing Method
Screen Printing vs. DTG vs. Embroidery vs. Other Options
If you’ve ever ordered custom apparel and thought…
“This didn’t turn out how I expected” — you’re not alone.
The truth is, most issues don’t come from bad design…
They come from choosing the wrong printing method.
At Custom Apparel Experts (CAE), we don’t just print—we guide you to the right process based on your goals, budget, and brand vision.
Let’s break it down
Find The Best Printing Method
First - What Are You Really Trying to Do?
To Find the Best Printing Method: Before choosing a print method, ask:
Are you ordering in bulk or small batches?
Does your design have a lot of detail or just a few colors?
Is this for everyday wear, athletics, or premium branding?
Do you need on-demand ordering?
Your answers determine everything.
Screen Printing: The Industry Workhorse
Best Printing Method For: Bulk orders, bold designs, brand consistency
If you’re printing for a team, school, company, or event—this is your go-to.
Why CAE recommends it:
Strong, vibrant ink that lasts
Most cost-effective at scale
Professional, retail-quality finish
Watch out for:
Not ideal for small runs
Each color adds setup cost
CAE Insight:
Screen printing is where you maximize value per shirt.
DTG (Direct-to-Garment): Detail + Flexibility
Best Printing Method For: Small runs, detailed artwork, online stores
This is the engine behind modern print-on-demand.
Why it works:
No minimums
Unlimited color capability
Perfect for artwork-heavy designs
Limitations:
Higher cost per piece in bulk
Works best on cotton
CAE Insight:
DTG is how you test designs without risk.
Heat Transfer / Vinyl: Customization King
Best Printing Method For: Names, numbers, personalization
Perfect for:
Sports uniforms
Small team orders
One-off custom pieces
Why it works:
Clean, sharp results
Fast turnaround
Ideal for individual customization
CAE Insight:
Use this when every piece needs to be different.
Sublimation: Performance + All-Over Design
Best Printing Method For: Athletic wear, polyester garments
Why athletes love it:
Ink becomes part of the fabric
No cracking, peeling, or fading
Lightweight, breathable
CAE Insight:
If you're building a premium athletic brand, this is your lane.
Embroidery: Premium, Professional, Built to Last
Best Printing Method For:
Polos, hats, jackets, hoodies
Corporate branding
Martial arts schools, instructors, and premium merchandise
What it is:
Embroidery uses stitched thread (instead of ink) to create a raised, textured design directly on the garment.
Why It Stands Out
High-end, professional look
Extremely durable (won’t fade, crack, or peel)
Adds perceived value to your brand
Ideal for logos and clean designs
Things to Consider
Not ideal for highly detailed or small text designs
Typically, higher cost per item than printing
Requires digitizing (one-time setup to convert your logo into stitch format)
CAE Insight:
Embroidery is how you instantly elevate your brand perception.
If screen printing is about scale…
Embroidery is about status and professionalism.
At the end of the day, choosing the right printing method isn’t just about ink, thread, or
fabric-it’s about how your brand is represented.
The difference between average and exceptional apparel often comes down to one thing: making the right decision before production ever begins.
That’s where we come in.
At Custom Apparel Experts, we don’t just take orders—we help you make smart, strategic choices that save time, reduce waste, and elevate your final product.
Whether you need a small run, a full brand launch, or a complete apparel system for your team, we’re here to guide you every step of the way.
Ready to get it right the first time?
Let’s build something that represents your brand the way it deserves.
Contact us today to get started.
Comments