Direct to Garment Printing: Full Process, Cost & Comparison (2025)

Direct to Garment (DTG) printing is transforming custom apparel with full-color, high-resolution prints directly on fabric. Learn how DTG works, its benefits, costs, and how it compares to DTF and screen printing in 2025.

The apparel printing industry has evolved rapidly in recent years. As demand for personalized, fast, and eco-friendly production grows, digital printing technologies are replacing traditional methods. Among these, Direct to Garment (DTG) printing stands out for its precision, flexibility, and ability to create detailed, full-color designs directly onto fabric.

DTG printing blends creativity with technology, allowing brands, small businesses, and print-on-demand services to produce custom garments quickly and sustainably. It eliminates setup complexity while maintaining professional quality.

This guide explores everything you need to know about DTG printing — from its process and benefits to costs, comparisons, and emerging trends shaping the industry.

What Is Direct to Garment (DTG) Printing?

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Direct to Garment (DTG) printing is a digital textile printing method that uses inkjet technology to apply water-based pigment inks directly to fabric. The inks are absorbed into the fibers, producing soft, detailed, and color-rich prints.

Unlike screen printing, which requires stencils for each color, DTG prints straight from a digital file — offering unlimited design freedom and faster turnaround. It’s especially effective for cotton and cotton-blend fabrics.

A Brief History

DTG printing entered the market in the early 2000s, with the first commercial printer, the “Revolution” by DIS. Soon after, brands such as Epson, Brother, Kornit, and Ricoh developed their own models, continuously improving speed, printhead precision, and ink quality. Today, DTG is a standard in custom apparel production worldwide.

How DTG Printing Works

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DTG printing follows a clear, multi-step process to ensure consistent quality and durability.

1. Design Preparation

Designs are created in programs such as Adobe Photoshop or CorelDRAW and processed through RIP (Raster Image Processor) software. This controls color balance, layering, and ink distribution for accurate reproduction.

2. Garment Pre-Treatment

Before printing, garments — especially dark ones — are coated with a pre-treatment solution that:

• Prevents ink from bleeding

• Improves color brightness

• Allows white ink to adhere properly

The garment is then heat-pressed to activate the coating.

3. Printing the Design

Once prepped, the garment is placed on the printer platen. The printer sprays ink directly onto the fabric with high precision. Machines such as Epson SureColor F2100 and Brother GTX Pro can achieve resolutions up to 1200 × 1200 dpi, capturing photographic detail and vibrant gradients.

4. Heat Curing

After printing, the garment is heat-cured at about 160 °C (320 °F) for two to three minutes. This step fixes the ink into the fibers, ensuring wash durability.

5. Final Inspection

Each garment is inspected for alignment, color accuracy, and curing quality before packaging.

Core Components of DTG Printing

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DTG technology relies on several interconnected elements:

• Printers: Specialized printers built for textiles ensure precision and reliability.

• Inks: Water-based, pigment-based, and OEKO-TEX® certified inks are used for safety and softness.

• Pre-Treatment: Essential for dark garments to improve adhesion and color intensity.

• Heat Equipment: Heat presses or tunnel dryers cure the prints.

• RIP Software: Manages color profiles and print layering for consistent results.

Advantages of DTG Printing

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DTG printing’s popularity stems from its versatility, eco-conscious process, and premium output.

• High-Resolution Quality: Produces lifelike, detailed prints suitable for complex artwork.

• No Setup Costs: Ideal for one-off or small-batch orders.

• Soft, Natural Feel: Ink soaks into fibers, keeping garments breathable.

• Eco-Friendly: Uses non-toxic, water-based inks and generates minimal waste.

• Fast Turnaround: Prints are produced directly from digital files in minutes.

• Unlimited Color Range: No color restrictions or extra setup for multi-color designs.

DTG Printing Compared to Other Methods

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DTG vs DTF (Direct to Film)

DTF printing involves printing designs onto PET film, coating them with adhesive powder, and heat-transferring them to garments. While both are digital methods, they serve slightly different needs.

• DTG produces a softer, natural finish, ideal for cotton fabrics.

• DTF works on a wider variety of materials, including polyester and nylon.

• DTG excels in fine detail and color blending, while DTF is better for high-volume or versatile material printing.

To learn more about this method, you can explore this in-depth guide on Direct to Film (DTF) Printing.

DTG vs Screen Printing

Screen printing uses stencils and multiple screens for each color. It’s highly efficient for bulk orders but less flexible for small batches.
DTG, in contrast, offers instant setup and unlimited design complexity, making it more practical for custom and short-run projects.

DTG vs Sublimation

Sublimation printing converts dye into gas and embeds it into polyester fabric. It’s excellent for sportswear and synthetic garments, while DTG remains best suited for natural fibers like cotton.
DTG delivers a soft, matte feel; sublimation produces a smooth, dye-infused finish.

Cost and Production Insights

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DTG printing costs vary based on design coverage, ink consumption, and garment type.
Typical industry averages include:

• Printer investment: $10,000 – $50,000

• Ink cost per shirt: $1 – $4

• Pre-treatment: $0.25 – $0.50 per garment

• Total production cost: roughly $2 – $6 per shirt

Retail prices for DTG-printed apparel generally range from $15 – $35, depending on complexity and brand markup. These figures are approximate and can differ by region and supplier.

DTG’s strength lies in on-demand production — ideal for small businesses, custom brands, and eCommerce operations.

Applications of DTG Printing

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DTG printing is widely used in:

• Print-on-demand stores such as Printful and Printify

• Independent fashion brands producing limited editions

• Corporate uniforms and promotional merchandise

• Art and photography apparel

Its flexibility and minimal setup make it perfect for modern, creative production models.

Trends and Future of DTG Printing

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In 2025, DTG printing continues to evolve with new technology and sustainability goals. Hybrid DTG/DTF printers, like Epson’s SureColor F2270, now combine both capabilities in one machine. Automation and AI are streamlining pre-treatment and color calibration, reducing human error and material waste.

The industry is also shifting toward bio-based inks, closed-loop water systems, and on-demand manufacturing, supporting a greener and more efficient fashion ecosystem.

Challenges and Limitations

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While DTG offers numerous benefits, there are still a few limitations:

• It performs best on 100% cotton garments.

• Production speed is slower than screen printing for large orders.

• White ink requires regular maintenance to prevent clogging.

• Pre-treatment quality directly affects final print results.

Despite these factors, new printer models and ink technologies are steadily improving reliability and reducing maintenance requirements.

Environmental Impact

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DTG is recognized as one of the most sustainable apparel printing methods. It uses eco-certified, water-based inks, produces little waste, and requires no chemical emulsions or screens. Because it supports on-demand production, DTG helps reduce overstock and fabric waste — major issues in the traditional fashion industry. Many manufacturers now incorporate energy-efficient printers and recyclable consumables to minimize environmental impact further.

Conclusion

Direct to Garment (DTG) printing has transformed how custom clothing is produced. Its blend of digital precision, eco-friendly operation, and creative flexibility makes it an ideal solution for both established brands and independent creators.

By enabling detailed, soft, and durable prints without setup waste, DTG embodies the next generation of sustainable apparel manufacturing. As hybrid systems, automation, and green technologies continue to advance, DTG printing will remain a driving force in the evolution of personalized fashion.

Frequently Asked Questions

1. What is DTG printing and how does it work?
DTG printing uses inkjet technology to print water-based pigment inks directly onto fabric. The printed garment is heat-cured to fix the design permanently.

2. Which fabrics work best for DTG printing?
DTG works best on 100% cotton or cotton-blend fabrics. Treated polyester can also be used, though results vary in color brightness.

3. How long do DTG prints last?
Properly cured and cared-for DTG prints typically last 40 – 60 washes, depending on fabric type, curing, and washing conditions.

4. Can DTG print on dark garments?
Yes, but dark fabrics require pre-treatment and a white ink underbase for accurate color reproduction.

5. Is DTG better than screen printing?
DTG is ideal for small runs and detailed, colorful designs. Screen printing is more cost-efficient for bulk orders with simple graphics.

6. How should DTG-printed garments be washed?
Wash inside out with cold water and mild detergent. Avoid bleach, high heat, or direct ironing on the print.

7. Is DTG environmentally friendly?
Yes. DTG uses non-toxic inks, minimal water, and supports on-demand production, making it one of the most sustainable apparel printing methods.