T-Shirt Printing Methods in India: Screen, DTG, Sublimation Compared

T-shirt printing methods in India

There are four main printing methods used for T-shirts in India, each suited to different quantities, designs, and fabric types. Choosing the wrong method is the most common reason for disappointing results or unexpectedly high costs.

Screen printing

Screen printing uses stencils (screens) to apply ink layer by layer onto the fabric. It is the gold standard for bulk T-shirt printing in India.

Minimum order: 50–100 pieces per colour/design
Cost per piece (100 units, 1 colour): ₹80–₹150
Best for: solid colours, simple logos, large quantities
Limitations: setup cost per colour (₹200–₹500), not suitable for photographic images or gradients

DTG (Direct to Garment)

DTG printing jets ink directly onto the fabric using a modified inkjet printer. No screens, no minimum order.

Minimum order: 1 piece
Cost per piece: ₹250–₹500 for a full-colour A4-size print
Best for: complex designs, photographs, small quantities, personalisation
Limitations: works best on 100% white cotton; colours on dark fabrics can fade faster

Heat transfer / sublimation

Heat transfer presses a design from transfer paper onto the fabric using heat and pressure. Sublimation is a specific type where ink becomes part of the fabric fibre.

Sublimation minimum: 1 piece, but only works on polyester (100%) or light-coloured fabrics
Cost per piece: ₹150–₹350 depending on print area
Best for: sportswear, all-over prints, synthetic fabrics
Limitations: sublimation does not work on cotton at all

Embroidery

Not strictly printing, but widely requested for corporate T-shirts and polos. Stitched designs are durable and premium.

Minimum order: 12–25 pieces typically
Cost per piece: ₹80–₹300 depending on stitch count and design complexity
Best for: logos on polos, corporate gifting, uniforms

Which method should you choose?

Under 50 pieces with a complex design → DTG. Over 100 pieces with a simple 1–3 colour logo → screen printing. Polyester sportswear or all-over print → sublimation. Premium polo or formal wear → embroidery.