Written By: Zach Dewhurst
(May 7, 2025)
Read Time: 11 Minutes
When you're starting a t-shirt printing business with DTF (Direct-to-Film) transfers and a heat press, it’s easy to get locked into the mindset of only offering what you can personally produce. But if you want to grow a sustainable, well-rounded business, understanding the full range of decoration methods—beyond just DTF—is a major advantage.
Here’s the key: you don’t need to master screen printing, embroidery, or DTG—but you should understand how they work, their pros and cons, and where they fit best. This knowledge makes you a more valuable resource to your customers and allows you to sell more effectively—even if you outsource the actual production to trusted contract decorators or promotional product suppliers.
If your goal is to grow a business—not just operate a machine—then you need to think like a solutions provider. Your customers don’t care how a shirt is printed. They care that it looks great, feels right, meets their budget, and holds up over time. By understanding all the common decoration methods, you can:
Recommend the best method for each job
Upsell customers on premium options
Avoid costly mistakes from using the wrong process
Build trust by sounding like an expert
Expand your services by outsourcing with confidence
And most importantly: you’ll stop leaving money on the table. When a customer needs embroidery or screen printing, don’t refer them elsewhere—offer it through your own brand and outsource the work. You stay the point of contact, grow your reputation, and earn the margin.
Here’s an overview of the most widely used apparel and promo decoration processes. Learn the basics of each so you can sell with confidence and outsource strategically.
1. Screen Printing
Best for: Bulk orders with the same design
Pros:
Very cost-effective for large runs
Vibrant colors and soft prints
Extremely durable
Cons:
Not ideal for small orders or full-color prints
Long setup time (burning screens, mixing inks)
Limited detail with halftones and gradients
When to Recommend:
50+ shirts with a 1–3 color logo
Corporate uniforms, events, schools, and teams
Customers who prioritize long-lasting prints
2. Embroidery
Best for: Professional wear, hats, jackets, polos
Pros:
High-end, textured look
Great for logos and monograms
Durable and wash-resistant
Cons:
Expensive for complex or large designs
Not ideal for lightweight garments
Limited in full-color artwork
When to Recommend:
Business polos, workwear, hats, beanies
Gifts, uniforms, or anything that needs to “look official”
When customers want a premium feel
3. Direct-to-Garment (DTG)
Best for: Full-color artwork on cotton shirts
Pros:
High detail and unlimited colors
Great for complex art and gradients
No minimum order quantities
Cons:
Slower production time
Works best only on 100% cotton
Less durable than DTF or screen printing
When to Recommend:
Small runs of artistic or photo-realistic designs
Online stores with a wide range of designs
Projects with lots of detail or multiple colors
Once you know what to recommend, build a trusted list of suppliers and decorators to fulfill those jobs. This might include:
Local contract shops for embroidery or screen printing
Online suppliers like SanMar, Alphabroder, or S&S Activewear paired with decorators
Promo distributors like Hit Promotional Products, PCNA, or Evans
Specialty partners for laser engraving, patches, or sublimation
Negotiate wholesale pricing where possible and ask about turnaround times, file formats, and pricing tiers. Create a system for quoting these services accurately, so you’re not guessing or cutting into your margins.
Being a successful custom apparel business owner doesn’t mean you have to do everything yourself. In fact, trying to master every process will burn you out and stall your growth. Instead, become a solutions provider—someone who knows the right method for every job and delivers great results through trusted partners.
Learning about screen printing, embroidery, DTG, HTV, sublimation, and promo decoration makes you a better advisor to your customers and a better business owner. You don’t have to touch a single screen or thread a single needle—but you should understand how each method works, when to use it, and how to sell it confidently.
