For custom T-shirts for companies, screen printing is the cheapest technique for medium and large runs with few colours; DTF (direct-to-film transfer) suits full-colour designs or small quantities; embroidery is the most durable, premium option for logos on polo shirts and sweatshirts. If you already have an apparel quote, Promopack cuts it by at least 10% with the same garment and technique and replies within 48 business hours.
Which technique should you choose for custom T-shirts for companies?
The choice depends on three things: the design (number of colours, gradients, size), the fabric (cotton, polyester, blends) and the quantity. This table sums up when each technique fits.
| Technique | Best for | Limits | Durability |
|---|---|---|---|
| Screen printing | 1-4 flat colours, medium and large runs, cotton | Fixed cost per colour and screen; gradients are tricky | High if the ink is properly cured |
| DTF (direct-to-film transfer) | Photos, gradients, many colours, small quantities | Film-like feel on large areas; less breathable | Medium-high |
| Embroidery | Chest logos, polo shirts, sweatshirts, caps | Very fine detail and large areas; cost per stitch count | Very high |
| Heat transfer vinyl | Individual names and numbers, few units | Not cost-effective on large runs | Medium |
| Sublimation | Full-colour designs on white or light polyester | Polyester and light shades only | Very high (ink bonded into the fabric) |
Which base garment should you choose?
The garment weighs more on the final price than the printing, and it’s the first thing the recipient notices. Look at the fabric weight (150-160 g/m² is usual for promotional T-shirts; 180-200 g/m² gives more body), the composition (combed cotton for screen printing and embroidery, polyester for technical wear and sublimation) and the sizing. A uniform order needs each person’s actual size; an event giveaway can use a standard size spread.
If the apparel is part of a welcome kit, it’s worth deciding on the garment and its presentation together. We cover this in merchandise packaging.
How do you prepare the design for each technique?
- Screen printing: a vector logo with separated colours (Pantone or reference), no gradients or with a defined halftone. State the position and size in centimetres.
- DTF: a 300 dpi file at actual size, with a transparent background. Avoid huge solid areas: they’re heavy and less breathable.
- Embroidery: clean vector artwork, with no text under 5-6 mm high. The workshop programs the embroidery (digitizing); that cost is paid once and reused on later orders.
How do you compare T-shirt quotes?
A comparable apparel quote states: garment model and reference, fabric weight and composition, colour, size spread, technique, number of colours and positions, print size, bagging and shipping. If two quotes differ on any of these points, you’re not comparing prices but different products.
With that specification fixed, Promopack offers the same order at least 10% cheaper: same garment, same technique, same colours and same quantity. You upload the quote, get a reply within 48 business hours and, if you like, a physical sample at cost only before production starts. If we can’t improve it, we tell you and it costs nothing.
When aren’t we the right option? If you need five T-shirts with different names for tomorrow, a print-on-demand shop is a better fit. And if you don’t have a previous quote, you can request one from scratch, describing the garment, technique and quantity. To see everything we customize in apparel, visit custom apparel.
Which mistakes keep coming up in company T-shirt orders?
- Ordering the medium size for everyone: you end up with spare Ms and not enough XLs. Ask for a size spread or sizes per person.
- Screen printing a design with gradients: the result looks nothing like the screen.
- Embroidering small text: it closes up and becomes unreadable.
- Not asking for a sample: fabric colour and the feel of the print can only be judged in the hand.
- Forgetting about washing: a uniform T-shirt gets washed many times; embroidery or well-cured screen printing holds up better than a cheap transfer.
How many T-shirts should you order, and how do you repeat the order?
For uniforms, allow at least two garments per person and a 10% reserve for new hires and replacements. For events, start from expected attendance and subtract the percentage that historically doesn’t pick up the gift. And keep the full specification (garment reference, Pantone, print position and size): repeating the order with the same supplier and the same spec sheet avoids paying for screens or embroidery programmes again and ensures the second run matches the first.
In short
- Screen printing for few colours and medium or large runs; DTF for full colour or few units; embroidery for durable logos on polo shirts and sweatshirts.
- The base garment weighs more than the printing on price and perception.
- A comparable quote details garment, fabric weight, sizes, technique, colours, positions and shipping.
- Promopack cuts a custom T-shirt quote by at least 10% with the same garment and technique, and replies within 48 business hours.
If you already have a quote for T-shirts or polo shirts for your team, upload it here and within 48 hours we’ll tell you how much you can save.
Frequently asked questions
Which is cheaper for company T-shirts, screen printing or DTF?
It depends on the quantity and colours. On medium and large runs with one or two colours, screen printing is usually cheaper because its fixed cost is spread out. For small quantities or full-colour designs, DTF avoids paying for a screen per colour.
Does embroidery work on thin T-shirts?
It does, but it shows more than on a polo shirt or sweatshirt: thin fabric can pucker around the embroidery. For lightweight T-shirts, a small embroidered logo works; for large designs, screen printing or DTF is better.
Can I order a sample before producing all the T-shirts?
Yes. At Promopack the physical sample is charged at cost only and lets you check the garment, colour and print before approving the full run.
