Screen Print vs DTG vs Embroidery: Choosing the Right Printing Method for Cannabis Apparel

When creating custom apparel for your cannabis brand, the printing method you choose significantly impacts the final product's look, feel, durability, and cost. Understanding the differences between screen printing, DTG (direct-to-garment), and embroidery helps you make informed decisions that serve your brand and budget.

Overview: The Three Main Methods

Before diving deep, here's a quick comparison:

| Factor | Screen Print | DTG | Embroidery | |--------|-------------|-----|------------| | Best for | Large orders, simple designs | Small orders, complex graphics | Premium look, durability | | Color limit | 6-8 colors typical | Unlimited | 15 colors typical | | Feel | Smooth, on fabric | Soft, in fabric | Raised, textured | | Durability | Excellent | Good | Exceptional | | Min order | 24-48 typical | 1 piece | 12-24 typical | | Unit cost | Low at volume | Consistent | Higher |

Screen Printing: The Industry Standard

Screen printing has been the dominant method for custom apparel for decades, and for good reason. It produces vibrant, durable prints at competitive prices for larger orders.

How Screen Printing Works

1. Screens created: Mesh screens with stenciled designs
2. Ink pushed through: Squeegee forces ink through mesh
3. Cured with heat: Flash dryer sets ink on fabric
4. Repeat per color: Each color requires its own screen

Screen Printing Advantages

Cost-Effective at Volume The per-unit cost drops significantly as quantities increase. At 100+ pieces, screen printing is often the most economical choice.

Vibrant Colors Specialty inks pop vibrantly, especially on dark fabrics. Plastisol inks create bold, opaque colors that stand out.

Exceptional Durability Properly cured screen prints last the life of the garment. They withstand countless wash cycles without significant fading.

Specialty Ink Options

• Metallic and glitter inks
• Glow-in-the-dark
• Puff (raised) printing
• Discharge printing for soft feel
• High-density raised effects

Consistent Results Once screens are made, every print is identical. Perfect for large orders requiring uniformity.

Screen Printing Limitations

Setup Costs Each color requires a separate screen, adding setup costs that make small orders expensive.

Color Limitations Most shops cap at 6-8 colors per design. Complex gradients and photographic images are challenging.

Minimum Orders Setup costs mean most printers require 24-48 piece minimums to be cost-effective.

Simple Designs Work Best Bold, graphic designs with limited colors print best. Subtle gradients and fine details can be problematic.

Best Uses for Screen Printing

• Large orders (48+ pieces)
• Simple logos and graphics
• Bold, limited-color designs
• Staff uniforms and event merchandise
• When durability is paramount

DTG (Direct-to-Garment): Digital Flexibility

DTG printing works like a large inkjet printer, spraying ink directly onto fabric. It's revolutionized small-order custom apparel.

How DTG Works

1. Garment prepped: Pre-treatment applied for ink adhesion
2. Loaded in printer: Garment placed on printing platform
3. Image printed: Inkjet heads spray water-based ink
4. Heat cured: Heat press sets the ink

DTG Advantages

No Minimum Orders Print a single shirt economically. Perfect for testing designs or producing limited editions.

Unlimited Colors Full-color photographs and complex gradients print beautifully. No extra cost for additional colors.

Soft Hand Feel Water-based inks absorb into fabric rather than sitting on top. The print feels like part of the shirt.

Quick Turnaround No screen setup means faster production. Same-day printing is possible for rush orders.

Easy Design Changes Update designs between prints at no cost. Test variations without commitment.

DTG Limitations

Higher Per-Unit Cost Consistent pricing means DTG becomes expensive compared to screen printing at larger quantities.

Durability Concerns While improving, DTG prints generally don't last as long as quality screen prints. Proper care is essential.

Best on Light Colors While DTG works on dark fabrics (with white ink base), results are best on light-colored garments.

Fabric Limitations Works best on 100% cotton. Performance fabrics, polyester, and blends can be problematic.

Print Size Limits Most DTG printers have maximum print areas smaller than screen printing capabilities.

Best Uses for DTG

• Small orders (1-24 pieces)
• Complex, multi-color designs
• Photographic images
• Testing new designs
• Limited edition drops
• On-demand merchandise

Embroidery: Premium Quality

Embroidery uses threaded needles to stitch designs directly into fabric. It creates a premium, professional appearance that printing cannot replicate.

How Embroidery Works

1. Design digitized: Artwork converted to stitch file
2. Fabric hooped: Garment secured in embroidery frame
3. Machine stitches: Computerized needles create design
4. Backing trimmed: Stabilizer removed or trimmed

Embroidery Advantages

Premium Perception Embroidery communicates quality and professionalism. It's the gold standard for corporate and upscale merchandise.

Exceptional Durability Properly done embroidery outlasts the garment itself. Thread doesn't fade, crack, or peel.

Tactile Quality The raised, textured feel of embroidery adds perceived value. People notice and appreciate the difference.

Works on Everything Embroidery works on virtually any fabric—performance materials, fleece, canvas, and more.

Consistent Across Colors Unlike printing, embroidery looks identical on any color garment. No concerns about ink opacity.

Embroidery Limitations

Higher Cost Digitizing fees plus longer production time means embroidery typically costs more than printing.

Detail Limitations Very small text and fine details don't translate well to thread. Designs need simplification.

Color Limitations Most machines run 15 colors maximum. Thread changes add production time and cost.

Size Limitations Large embroidery designs are expensive and can distort fabric. Best for smaller logos and text.

Puckering Risk Improper hooping or thin fabrics can pucker around embroidery. Quality execution matters.

Best Uses for Embroidery

• Hats and caps (the standard)
• Polo shirts and professional wear
• Left-chest logos
• Jackets and outerwear
• Premium merchandise
• Staff uniforms for upscale environments

Choosing the Right Method: Decision Framework

Consider Your Order Size

1-24 pieces: DTG typically makes most sense 24-48 pieces: Compare DTG and screen printing quotes 48+ pieces: Screen printing usually wins on cost Any size premium items: Consider embroidery

Consider Your Design

Simple logo, limited colors: Screen printing Complex graphics, many colors: DTG Photographic images: DTG Small, professional logo: Embroidery Large, detailed design: Screen printing with specialty techniques

Consider Your Product Type

T-shirts: Any method works; match to order size and design Hoodies: Screen printing or embroidery Hats: Embroidery is standard; some printing options exist Polos: Embroidery preferred for professional look Performance wear: Embroidery or specialty printing

Consider Your Brand Position

Value-focused: Screen printing maximizes budget Premium positioning: Embroidery communicates quality Creative/artistic: DTG enables complex designs Professional/corporate: Embroidery sets the standard

Hybrid Approaches

The best merchandise programs often combine methods.

Example: Dispensary Merchandise Line

• Staff polos: Embroidered left-chest logo
• Customer t-shirts: Screen printed back design
• Limited edition drops: DTG printed artistic designs
• Hats: Embroidered front panel

Example: Event Merchandise

• Mass giveaway tees: Screen printed simple logo
• VIP t-shirts: DTG printed exclusive design
• Staff uniforms: Embroidered polos

Quality Considerations for Cannabis Brands

When selecting methods for your custom cannabis accessories and apparel, consider:

Brand Consistency Your merchandise reflects your brand. Cheap printing on cheap blanks damages brand perception. Invest in quality that matches your cannabis products.

Longevity Customers wearing faded, cracked prints reflect poorly on your brand. Choose methods and suppliers that ensure durability.

Compliance Ensure designs and products comply with local cannabis regulations. Avoid anything that could appeal to minors or make prohibited claims.

Versatility Build a merchandise program that uses multiple methods appropriately. Match the method to the product and purpose.

Working with Your Supplier

Quality results depend on quality partners. When selecting a supplier for your apparel:

Ask About Methods

• What printing methods are available?
• What are minimum orders for each?
• Can they recommend the best method for your design?

Request Samples

• See actual examples of their work
• Check print quality and durability
• Evaluate blank quality

Get Mockups Request a mockup to see your design on actual products before committing to production.

Discuss Quantity Breaks Understand how pricing changes with quantity. Sometimes slightly larger orders unlock significant savings.

Making Your Decision

The best printing method depends on your specific situation:

1. Define your needs: Order size, design complexity, product types
2. Set your budget: Per-unit targets and total investment
3. Consider your brand: Premium, value, creative positioning
4. Get quotes: Compare options from quality suppliers
5. Review samples: See actual quality before ordering

There's no universally "best" method—only the best method for your particular project. Understanding the strengths and limitations of each helps you make informed decisions that serve your brand.

Conclusion

Screen printing excels for larger orders with simpler designs. DTG enables small runs with complex graphics. Embroidery delivers premium perception and exceptional durability. The best cannabis merchandise programs use all three methods strategically.

Explore custom cannabis accessories and apparel options to see what's possible for your brand. Request mockups to visualize your designs before committing to production.