DTF vs. Screen Print for Bulk Orders

If you’re running a growing clothing brand or printing merch for large events, chances are you’ve asked: “Should I use screen printing or DTF for bulk orders?” Both are capable of producing high-quality prints—but they work very differently. Knowing which process is more cost-effective, flexible, and efficient can save you time and money.

In this guide, we compare Direct to Film (DTF) and traditional screen printing to help you make the right choice for your next large apparel project.

🖨 What Is Screen Printing?

Screen printing is a classic method that uses stencils (screens) and ink to press designs directly onto fabric. Each color requires a separate screen, which makes setup time-intensive—but it’s a proven solution for large orders with simple artwork.

✅ Pros:

  • Ideal for high-volume single-color prints

  • Great for bold, flat artwork

  • Inks can produce thick, durable finishes

  • Long-term industry standard

❌ Cons:

  • High setup time and cost

  • Not ideal for multicolor or detailed designs

  • Limited fabric compatibility (mostly cotton)

  • Poor scalability for small batch variations

🧵 What Is DTF Printing?

DTF (Direct to Film) printing is a newer method where designs are printed onto film using CMYK+White ink, cured with adhesive powder, and then heat pressed onto garments.

✅ Pros:

  • Full-color printing with gradients & detail

  • Works on cotton, polyester, blends, fleece & more

  • No setup, no screens, no mess

  • Perfect for variable designs and multiple SKUs

  • Affordable for small and large batches

  • Hot or cold peel options

❌ Cons:

  • Slightly higher cost per unit than screen printing in very large batches

  • Requires a heat press for application

🆚 Bulk Order Comparison: DTF vs. Screen Print

Let’s break down the most important factors:

Feature Screen Printing DTF Printing
Setup Time Long (screens & alignment) None (upload & print)
Color Capability 1–6 colors typical Full color, photo-quality
Small Batch Friendly ❌ No ✅ Yes
Variable Designs ❌ No ✅ Yes
Fabric Compatibility Limited Universal (cotton, poly, fleece)
Durability High High (50+ washes)
Turnaround Speed Slower for setup Fast (24–48 hours)
Ideal Use Case 1 design, 100+ shirts 10–500 shirts, varied artwork

💥 The Verdict for Bulk Orders:

Screen printing still makes sense for extremely large runs (e.g. 1,000+ units) of a single design with 1–2 colors.

But if your order involves:

  • Full-color artwork

  • Multiple designs

  • Mixed garment types

  • Quick turnaround

  • Small-to-mid-size batches (10–500 units)

DTF is the clear winner. It's more versatile, faster to start, and reduces the need for stockpiling large inventories.

🛒 Get Started with DTF Bulk Printing

Express DTF Supply specializes in high-quality, fast-turnaround gang sheet printing with shipping across the USA. Based in Humble, TX, we help you print more and waste less.

Popular options:

Fast Turnaround:

✅ 24–48 hour processing
✅ Same-day printing available
✅ Local pickup in Humble, TX
✅ Nationwide shipping with tracking

Press Instructions:

  • Temp: 305°F (150°C)

  • Time: 10–12 seconds

  • Pressure: Medium to High

  • Peel: Hot or Cold

  • Optional: Repress for improved finish

💬 What Customers Say:

⭐ “We switched from screen printing for our merch drops—DTF lets us offer more designs with less inventory.”
⭐ “DTF gang sheets let us press exactly what we sell. Our bulk orders are faster and cheaper.”
⭐ “Turnaround is amazing. We can run 100-shirt batches with multiple graphics in 48 hours.”

📞 Need help planning a bulk order?

  • Visit our FAQs

  • Contact Us for layout help or wholesale pricing

  • Learn more About Us

Start printing better today:

🛒 Build Your Own Gang Sheet
🛒 Upload Ready DTF Gang Sheet