The short answer: Under 6 shirts, DTF printing is the right choice — no setup fees, no minimums, full color. For orders of 6 or more, screen printing delivers better per-shirt value and exceptional durability. At ARK, we do both in-house and will recommend the right method for your order.
What Is DTF Printing?
DTF stands for Direct to Film. Your design is printed in full color onto a special transfer film, coated with a heat-activated adhesive, and then pressed onto your garment with a heat press. The transfer bonds to the fabric fibers and produces a smooth, flexible print.
Because DTF doesn't require screens or color separations, there's no setup cost — which means it's just as economical to print 1 shirt as it is to print 5. It handles any design complexity: gradients, photographs, fine detail, and unlimited colors all work perfectly.
What Is Screen Printing?
Screen printing uses a fine mesh screen to push ink directly through onto the fabric. Each color in your design requires a separate screen, and those screens have a setup cost. Once the screens are made, however, each additional shirt costs very little — so the per-shirt price drops significantly as your order size grows.
Screen printing produces ink that's embedded into the fabric rather than sitting on top of it. It's extremely durable and is the industry standard for bulk garment printing. It works best for designs with clean lines and a limited number of solid colors.
DTF vs. Screen Printing: Side by Side
| Factor | DTF Printing | Screen Printing |
|---|---|---|
| Minimum order | 1 shirt — no minimum | 6+ shirts at ARK |
| Setup cost | None | Screen fees per color (amortized across order) |
| Color complexity | Unlimited — gradients, photos, fine detail | Best for 1–6 solid colors |
| Best for | Small orders, complex designs, samples | Bulk orders, simpler designs, teams & events |
| Durability | High — flexible, wash-resistant | Very high — ink bonds with fabric fibers |
| Turnaround (at ARK) | 3–5 business days | 7–14 business days |
| Ships nationally | Yes | Yes |
Choose DTF When…
- You need fewer than 6 shirts
- Your design has many colors, gradients, or photographic elements
- You want a prototype before committing to a larger run
- It's a one-time event (birthday, family reunion, small team)
- You need a single custom shirt
- You want to test a design before bulk ordering
Choose Screen Printing When…
- You're ordering 6 or more shirts
- Your design uses 1–4 solid colors
- You want maximum cost-efficiency on bulk
- You need team uniforms, event shirts, or merch runs
- Long-term durability is a top priority
- You're ordering the same design repeatedly
How ARK Handles Both
ARK does DTF printing and screen printing in-house in Colorado Springs — you don't need to choose upfront or know which method you need. Just tell us your quantity and design, and we'll recommend the right method and give you an accurate quote.
Small order? We'll route it to DTF automatically — no setup fees, no minimums. Larger order? Screen printing, with per-shirt pricing that gets more competitive the more you order. Both methods are available for local pickup or nationwide shipping.