Buyers often compare the cost of direct-to-garment (DTG) and screen printing to decide which method fits budget and volume. The primary cost drivers are setup fees, per-unit ink or ink-and-color costs, and labor time. This article presents clear price ranges in USD, with practical guidance for different order sizes and print complexities.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| DTG setup | $10 | $40 | $150 | Includes pre-treatment and printer calibration |
| DTG per-unit ink | $1.50 | $3.50 | $6.50 | Color count impacts total |
| DTG labor (per hour) | $25 | $40 | $80 | Machine time and prep counted |
| Screen setup (per-color) | $20 | $60 | $120 | Higher for complex art |
| Screen print per-unit | $0.50 | $1.20 | $2.50 | Running ink, emulsion, and shop overhead |
| Plates and setup amortization | $0 | $0.50 | $1.50 | Declines with higher volumes |
| Minimum run impact | Often 1–12 shirts | 10–12 shirts typical | 25+ shirts common for best value | |
| Delivery/shipping | $5 | $15 | $40 | Depends on distance and rush |
Overview Of Costs
Cost ranges show total project estimates and per-unit ranges for both DTG and screen printing. DTG generally incurs higher per-unit ink costs and setup for small runs, while screen printing benefits from lower per-unit pricing at higher volumes. Assumptions: standard cotton shirts, full-color artwork, mid-range garment weight.
Cost Breakdown
DTG: total project range versus per-unit ranges depend on print count and color depth. A typical 24-shirt run with a multi-color image might range from $360 to $1,040, including setup and ink. In per-unit terms, DTG may run $15–$45 per shirt for small runs, rising with color coverage and pre-treatment needs. Assumptions: one location, standard 14–16 oz cotton garments, single-side printing.
Screen printing: project range combines setup, inks, and press time with cheaper per-unit costs as volumes grow. A 500-shirt run can cost roughly $2,100–$9,000, translating to $4–$18 per shirt depending on number of colors and garment type. Assumptions: 1–4 colors, aluminum or steel screens, basic flash cure, standard tees.
What Drives Price
Color count and print area strongly influence costs in screen printing, since more colors require more screens and longer press time. For DTG, color depth and image complexity drive ink consumption and print head time. Setup complexity, like large pre-treatment or multi-location prints, adds fixed costs to both methods. Assumptions: 8–12 color DTG image vs 2–4 color screen print.
Ways To Save
Buy in bulk to reduce unit costs and align artwork to a practical color count. For DTG, simplifying the artwork or using fewer color transitions lowers ink and head-dwell time. For screen printing, combining color passes or using spot colors reduces setup and screen costs. Assumptions: mid-range garment, standard poly/cotton blends, basic finishes.
Regional Price Differences
Prices vary by region and shop capacity. In the Northeast urban market, screen printing tends to be higher due to labor and facility costs, yielding roughly +8% to +15% over national averages. The Midwest suburban market often shows mid-range pricing, while rural Western markets can be -5% to -12% lower for similar capabilities. Assumptions: shop size, local wages, and equipment depreciation affect final quotes.
Labor, Time & Efficiency
Estimating labor hours per shirt matters for both methods. DTG labor may be 3–6 minutes per shirt for a single-color image and 8–12 minutes for full color, excluding pre-treatment. Screen printing labor depends on color count and run size; a single-color print might take 1–2 minutes per shirt on a modern press, whereas a 4-color build could extend to 3–5 minutes per shirt plus setup. data-formula=”labor_hours × hourly_rate”> Assumptions: standard sizes, shop workflow, and no rush orders.
Regional Price Differences
- Urban Northeast – Higher baseline costs; screen printing around $6–$18 per shirt for small runs; DTG often $12–$40 per shirt.
- Suburban Midwest – Balanced pricing; screen printing typical $4–$12 per shirt; DTG $10–$30 per shirt.
- Rural West – Slight discounts; screen printing $3–$9 per shirt; DTG $9–$28 per shirt.
Real-World Pricing Examples
Basic scenario: 24 shirts, 1-color screen print on standard tees; no rush. Total: $180–$360; per-shirt $7.50–$15. Assumptions: 1 color, standard ink, basic wash test.
Mid-Range scenario: 24 shirts, full-color DTG on 100% cotton; includes pre-treatment and curing. Total: $360–$1,040; per-shirt $15–$43. Assumptions: high-color image, standard pre-treatment done.
Premium scenario: 500 shirts, multiple colors, screen printing with multiple passes and high-end fabrics; includes plates and inks. Total: $2,100–$9,000; per-shirt $4–$18. Assumptions: 4-color process, spot colors, higher-end shirts.
Assumptions: region, specs, labor hours.