The Drawbacks of Common T-Shirt Printing Methods: What You Need to Know Before You Choose

The Drawbacks of Common T-Shirt Printing Methods: What You Need to Know Before You Choose

In the world of custom apparel, customers often focus on price, color options, or shirt material—but one of the most important decisions is which printing method to use. Each method has its strengths, but what most people don’t realize is that every technique also comes with limitations. Understanding these drawbacks helps organizations avoid printing mistakes, budget surprises, and quality issues down the line.

Below is a breakdown of the most common printing methods—and the cons you should be aware of before placing your next order.

 

1. Screen Printing: The Industry Standard, But Not Always Ideal

Screen printing is one of the most popular methods in the apparel world. It delivers long-lasting prints, bold colors, and excellent durability. However, despite its reputation, it’s not perfect.

Cons of Screen Printing

High Setup Costs for Small Orders

Each color in your design requires its own screen, setup, and proofing.

For small runs—especially under 24 pieces—the setup cost can make screen printing much more expensive than expected.

Not Ideal for Multicolor or Highly Detailed Artwork

While modern screen printers can achieve impressive detail, extremely intricate designs or gradients often don’t translate perfectly.

CMYK or full-color photographic images are especially difficult.

Limited Color Count

Screen printing is best for designs with fewer colors.

If you want 8+ colors in a single graphic, the cost skyrockets.

Ink Thickness Can Be Felt

Because plastisol ink sits on top of the fabric, large solid prints can feel heavy, rubbery, or thick—especially in hot weather.

Environmental Drawbacks

Screen printing involves chemicals, inks, emulsions, and water usage. Many shops use eco-friendly options, but the process itself is more resource-heavy compared to digital methods.

 

2. Direct-to-Film (DTF): Versatile but Not Perfect

DTF printing has exploded in popularity for its flexibility and ability to print bright, detailed designs on almost any fabric. But it comes with its own set of issues.

Cons of DTF

Thicker Hand Feel

Because DTF uses a powder adhesive and printed film, the final print sits more heavily on the shirt.

Large designs can feel plastic-like or stiff.

Less Breathable

A full-front DTF design doesn’t allow airflow through the print area.

This can make shirts feel warmer and less comfortable, especially for sports or outdoor activities.

Potential for Cracking Over Time

High-quality DTF holds up well, but cheaper materials can crack or peel—especially after dozens of washes.

Not as Premium as Screen Printing

DTF is fantastic for complex artwork and short runs, but for high-end retail apparel, it may not look as refined as traditional screen printing or DTG.

 

3. Direct-to-Garment (DTG): Great for Detail, But Very Limited

DTG uses inkjet technology to print directly into the fabric fibers, making it excellent for complex or photographic designs. Still, it has notable drawbacks.

Cons of DTG

Requires High-Quality, High-Cotton Garments

DTG performs best on:

• 100% cotton
• Ringspun cotton
• Smooth, tightly woven fabrics

Blends and polyester don’t absorb the ink well, leading to faded or muted results.

Colors Can Look Less Vibrant

While DTG can print millions of colors, it often appears softer or less saturated than screen printing—especially on dark shirts.

Pretreatment Issues

Dark garments require a pretreatment solution that can:

• Leave visible stains if applied unevenly
• Cause the final print to feel stiff
• Produce inconsistent results across large orders

Lower Durability Than Screen Printing

DTG prints penetrate the fabric but don’t bond as strongly as plastisol ink.

Frequent washing can fade the design earlier than other methods.

Slower Production Timeline

DTG prints one shirt at a time, so large orders can take significantly longer to produce.

 

4. Sublimation: Vibrant and Permanent, But Extremely Limited

Sublimation creates stunning, permanent prints—but only under very specific conditions.

Cons of Sublimation

Only Works on Polyester

This is the biggest drawback.

You must use:

• 100% polyester shirts
• Sublimation-coated garments
• Light-colored fabrics

You cannot sublimate on:

• Cotton
• Dark shirts
• Most blends

This eliminates many common apparel options.

Vintage or Washed-Out Look on Lower Polyester Counts

Even a 65/35 blend will result in a more faded, distressed appearance.

Color Limitations on Dark Fabrics

Sublimation ink is translucent.

On black or dark shirts, the design barely shows up at all.

Design Permanence Can Be a Downside

The ink becomes part of the fibers—great for durability, bad if you want texture or opacity.

 

5. Heat Transfer Vinyl (HTV): Great for Simple Work, But Not for Scale

Vinyl is often used for names, numbers, and simple graphics. It’s easy to apply and offers excellent opacity. But it’s not ideal for most full designs.

Cons of Vinyl

Very Heavy Feel on the Shirt

Vinyl sits on top of the fabric and can feel:

• Thick
• Plastic-like
• Less flexible

Large vinyl prints can feel uncomfortable.

Low Durability With Heavy Use

Over time, vinyl can:

• Crack
• Peel
• Lift at the edges

Especially after high heat or heavy washing.

Poor Airflow

Just like DTF, vinyl blocks airflow completely under the print area.

Limited Detail

Fine lines and tiny text are difficult to weed (remove excess material) and often don’t hold up well over time.

Not Scalable for Large Orders

Each vinyl piece must be cut and applied individually.

This makes large runs extremely labor-intensive and expensive.

 

6. Other Methods and Their Drawbacks

Embroidery

Beautiful and premium, but:

• Not great for thin shirts
• Heavy and stiff on lightweight fabrics
• Cannot capture fine detail well
• More expensive than printed methods

CAD-Cut Transfers

Good for small runs, but:

• Similar drawbacks to vinyl
• Colors can be limited
• Not ideal for high wear garments

Plastisol Transfers

Useful for certain designs, but:

• Can crack if not applied correctly
• Feel nearly identical to vinyl or DTF
• Not as durable as true screen printing