DTG vs. Screen Printing vs. Embroidery: Small-Batch Breakdown

Calculate break-even quantities, setup fees, and wash durability across modern custom decoration methods.

Direct-to-Garment (DTG) & Direct-to-Film (DTF): Best for 1 to 24 Units

DTG and DTF require zero screen setup charges and handle full-color photographic gradients effortlessly. They are ideal for prototyping new designs, testing audience demand, and fulfilling on-demand orders.

Traditional Screen Printing: Best for 36+ Units with 1–4 Colors

Once your order crosses 36 pieces of a single design with 1 to 3 spot colors, plastisol or water-based screen printing dramatically lowers your cost per unit while delivering vibrant, long-lasting ink opacity.

Embroidery: High Perceived Value on Hats & Heavyweight Fleece

Digitizing a logo for embroidery costs a one-time setup fee, but stitched emblems on unstructured dad hats, beanies, and quarter-zips command the highest perceived retail value.