DTG vs Screen Printing Australia: Which Is Right For Your Order?
If you've ever tried to order custom printed t-shirts in Australia, you've probably come across two main options: DTG (Direct-to-Garment) printing and screen printing. Both produce great results — but they work very differently, and choosing the wrong method can cost you time, money, and a lot of frustration.
This guide breaks down everything you need to know, based on real-world experience printing thousands of garments across Australia.
What Is DTG Printing?
DTG printing works like a regular inkjet printer — but instead of paper, it prints directly onto fabric. A specialised printer jets water-based ink into the fibres of the garment, producing full-colour, photo-quality prints with no setup fees and no minimum order requirements.
Best for:
- Small runs (1–50 pieces)
- Complex, full-colour artwork or photographs
- On-demand and personalised orders
- Startups and small businesses testing designs
What Is Screen Printing?
Screen printing is the traditional method. Each colour in your design is separated and pushed through a mesh screen onto the garment using ink. It produces incredibly vibrant, durable prints — but requires a separate screen for every colour, which means setup costs and minimum order quantities.
Best for:
- Large runs (50+ pieces)
- Simple designs with 1–4 solid colours
- Bulk uniforms, event merchandise, and promotional apparel
- Orders where per-unit cost needs to be as low as possible
DTG vs Screen Printing: Side-by-Side Comparison
| Factor | DTG Printing | Screen Printing |
|---|---|---|
| Minimum Order | ✅ No minimum (even 1 piece) | ❌ Usually 24–50+ pieces |
| Setup Cost | ✅ None | ❌ $20–$50+ per colour |
| Colour Complexity | ✅ Unlimited colours, gradients, photos | ⚠️ Best with 1–4 solid colours |
| Per-Unit Cost (Small Run) | ✅ Cost-effective for small quantities | ❌ Expensive due to setup fees |
| Per-Unit Cost (Large Run) | ⚠️ Higher than screen printing at scale | ✅ Very cost-effective at 100+ pieces |
| Turnaround Time | ✅ 1–3 business days | ⚠️ 5–10 business days |
| Print Durability | ✅ Excellent with proper care | ✅ Excellent, very wash-resistant |
| Best Fabric | 100% cotton or high cotton blends | Most fabrics |
| Personalisation | ✅ Each piece can be different | ❌ All pieces must be identical |
The Real Cost Difference in Australia
Let's look at a real example. Say you want 10 custom t-shirts with a full-colour logo:
DTG: No setup fee. Pay per shirt. Total might be $150–$200 for 10 pieces. Done in 2 days.
Screen Printing: Setup fee of $40–$80 per colour (say 3 colours = $150 setup) + per-shirt cost. For 10 shirts, you're looking at $250–$350+, and it takes a week.
At 10 pieces, DTG wins easily. But flip it to 200 pieces with a simple 2-colour design, and screen printing becomes significantly cheaper per unit.
The break-even point in Australia is typically around 50–75 pieces for simple designs. Below that, DTG is almost always the smarter choice.
Print Quality: What Does Each Method Actually Look Like?
DTG Print Quality
Modern DTG printers produce stunning results on 100% cotton garments. Colours are rich, gradients are smooth, and photographic detail is preserved. The print has a soft hand feel — it doesn't sit on top of the fabric, it becomes part of it.
One thing to note: DTG prints on dark garments require a white underbase layer, which can slightly affect the softness of the print. On white or light garments, the result is exceptional.
Screen Print Quality
Screen printing produces bold, vibrant colours that pop — especially on dark garments. The ink sits on top of the fabric, giving prints a slightly raised texture. For simple logos and text, screen printing is hard to beat in terms of visual impact and longevity.
Which Method Is Right For You?
Here's a simple decision guide:
Choose DTG if:
- You need fewer than 50 pieces
- Your design has many colours, gradients, or photographic elements
- You need fast turnaround (under a week)
- You want to personalise each garment differently
- You're testing a new design before committing to a large run
- You have no minimum order budget
Choose Screen Printing if:
- You need 100+ identical pieces
- Your design is simple (1–4 solid colours)
- You're producing bulk uniforms or event merchandise
- Per-unit cost is the top priority
Why Diyprint Uses DTG for Most Australian Orders
At Diyprint, we specialise in DTG printing because it gives our customers the most flexibility. Whether you need 1 shirt or 500, we can print it — with no setup fees, no minimum orders, and a turnaround of just 1–3 business days.
We print locally in Australia, which means faster delivery, better quality control, and real support from a team that actually picks up the phone.
If you're not sure which method suits your order, get a free quote and we'll recommend the best option for your budget and timeline.
Frequently Asked Questions
Is DTG printing durable?
Yes. DTG prints last well when cared for correctly — wash inside out in cold water and avoid tumble drying on high heat. With proper care, a DTG print can last the life of the garment.
Can I mix DTG and screen printing in one order?
Generally no — each method requires different setup and equipment. For most small-to-medium Australian businesses, DTG is the practical all-in-one solution.
What file format do I need for DTG printing?
PNG files with a transparent background at 300 DPI are ideal. We also accept AI, PDF, and PSD files. Not sure if your file is print-ready? Send it to us and we'll check it for free.
Does DTG work on dark shirts?
Yes — we print on dark garments using a white underbase layer to ensure colours stay vibrant. The result is excellent on quality cotton garments like our 200GSM heavyweight tees.