When it comes to producing activewear in large volumes, choosing the right printing method can directly affect your costs, product quality, and delivery timeline. In recent years, DTF printing (Direct to Film) has emerged as a strong contender alongside traditional screen printing services, particularly in Vietnam’s fast-growing textile manufacturing scene.
Many brands assume that screen printing is always the cheaper option for bulk orders. But for modern activewear – especially those made with polyester blends or featuring full-color graphics – that assumption doesn’t always hold true. If you’re in the business of bulk garment decoration for performance apparel, it’s time to re-evaluate.
In this article, we take a deep dive into both methods to help you make an informed choice for your next production run of sportswear in Vietnam.
The Activewear Challenge: Function Meets Design
Activewear is not just about looking good – it needs to perform. Whether it’s gym gear, running shirts, team jerseys, or yoga outfits, these garments are exposed to intense activity, sweat, frequent washing, and constant movement. That means any printing method you choose must be durable, breathable, and able to hold up under pressure.
The challenge becomes even more complex when your designs include logos with fine detail, gradients, or a wide color palette. Combine that with moisture-wicking, stretchy fabrics like polyester or spandex, and you’re now dealing with a high-stakes printing decision.
Understanding Screen Printing Services for Sportswear
Screen printing services have long been the standard for bulk apparel decoration. The process involves creating stencils (screens) for each color in the design and pushing ink through them onto the garment. It’s ideal for simple logos and solid color designs, particularly when you’re producing thousands of identical pieces.
In terms of durability, screen printing excels. The inks bond well to fabric, and the result can withstand many wash cycles without cracking or fading. It’s especially well-suited to cotton or cotton-blend fabrics, and when done correctly, offers a clean, professional finish.
However, the more complex your design, the more time and cost are added to the setup. Every new color requires a new screen, and every adjustment during sampling costs both time and money. Additionally, polyester sportswear can sometimes present challenges for traditional inks, especially without specialty underbase or ink formulations.
DTF Printing: The Modern Alternative
DTF printing is a newer method that involves printing your design onto a film, applying a powder adhesive, and then heat-pressing the design onto the garment. Unlike DTG (Direct to Garment), DTF works well with a broader range of fabrics – including polyester and stretch materials often used in activewear.
One of DTF’s biggest advantages is its ability to reproduce full-color designs – including gradients, photographic detail, and intricate logos – without additional setup costs. There’s no need to separate colors or create physical screens. That makes it a fast, flexible choice for collections with a wide variety of graphics or frequent updates.
For performance wear, DTF holds up surprisingly well under stress. The adhesive bond is strong, making it resistant to cracking and fading, even after repeated movement and washing. The process also results in a smooth, slightly raised texture that feels durable but not bulky.
Comparing the Costs: Screen vs. DTF for Bulk Production
When it comes to screen printing services, cost per unit drops significantly as quantity increases. This is due to the high initial setup costs (screens, alignment, and test runs), which are amortized over large volumes. If you’re printing 5,000 identical shirts with a simple two-color logo, screen printing is probably your most economical choice.
But once your order involves: more than four colors, multiple graphics or SKUs, polyester or spandex garments or shorter lead times,… DTF can actually become more affordable and efficient.
With DTF, the setup is minimal. You can move from design to production quickly. And because the cost doesn’t rise with additional colors, it becomes an appealing solution for brands that value speed and design flexibility.
For mid-volume orders (say, 500 to 2,000 units), or collections that include design variations, DTF often matches or beats screen printing on cost. It also saves time – crucial for seasonal drops, promotions, or market testing.
Quality and Feel: What Your Customers Will Notice
Activewear customers expect comfort and long-lasting performance. Screen printing typically results in a flatter, smoother print that integrates well with the fabric, especially when printed on natural fibers. On polyester, however, issues like dye migration or ink cracking may arise if not properly managed.
DTF prints tend to sit slightly on top of the fabric, giving a very vibrant look. While some customers may notice a slight difference in texture, most won’t mind – especially if the print remains intact after multiple wears and washes.
At In-Credible, we’ve refined our bulk garment decoration process to ensure both screen and DTF prints pass quality and durability tests before going into full production. Our team offers recommendations based on fabric, artwork complexity, and customer expectations.
Which Should You Choose for Your Sportswear in Vietnam?
Here’s how we typically advise:
- Choose screen printing services if your order is very large, the design is simple, and your fabric is cotton or cotton-blend.
- Go with DTF printing if you’re using polyester or stretch fabric, have detailed or multi-color artwork, and want faster production.
That said, your specific production goals should guide your decision. Do you need fast turnaround for a campaign or event? Do your designs vary across SKUs? Do you anticipate repeat orders with customizations?
These are the kinds of questions we help answer every day at In-Credible. With over a decade of experience serving sportswear brands in Vietnam, we’re equipped to recommend the most cost-effective and visually impressive solution for your needs.
Final Thoughts
Screen printing services remain a solid choice for high-volume, low-variation orders. But in today’s apparel market – especially in the fast-moving sportswear segment – DTF printing is proving to be a serious competitor. Its flexibility, speed, and ability to handle synthetic fabrics make it ideal for activewear brands that need quality without compromise.
As you plan your next bulk run of sportswear in Vietnam, don’t rely on outdated assumptions. Evaluate your design needs, material choices, and timelines carefully. And partner with a team that offers both traditional and modern printing technologies, along with the insight to match them to your brand.
Ready to find out which printing method works best for your collection?
Explore In-Credible’s custom printing solutions at In-Credible or contact us directly to speak with our production team.