Screen printing has long been considered the gold standard for large apparel runs. Known for its durability, vibrancy, and cost efficiency at scale, it’s often the first method that comes to mind for bulk garment printing. But times have changed. Newer printing technologies – particularly DTF printing and hybrid methods – are shifting the landscape, especially for multi-color designs and short lead times.
So here’s the question brands should be asking: Is screen printing really the most cost-effective option for my project?
The answer is not always. In this article, we’ll walk through why screen printing is no longer the automatic choice for large orders, and how modern alternatives might be better suited for your business – depending on your artwork, timeline, and production goals.
The Real Cost of Screen Printing
At first glance, screen printing seems cheap for bulk orders because the unit price decreases as the quantity increases. But this cost-efficiency only kicks in under certain conditions:
- You have a simple design with one to three colors
- You’re printing hundreds or thousands of the same graphic
- You don’t need to rush the turnaround
What many people overlook is the setup cost. Screen printing requires separate screens to be made for each color in your design. The more colors involved, the more screens – and the more time and labor required to set up. This can eat into your margins if your order isn’t high enough to absorb those costs.
Additionally, each screen needs alignment (or registration), test prints, and manual adjustments before production starts. If you’re working on a tight deadline, this setup phase becomes a bottleneck. And if your design changes at the last minute? The entire process may need to be restarted.
In short, screen printing is most affordable only when your order volume is high, your design is simple, and your timeline is flexible.
The Better Choice for Multi-Color Designs
One of the biggest misconceptions is that screen printing is still cost-effective for colorful designs at high volumes. In reality, when your artwork includes gradients, photographic detail, or more than four colors, the cost of screen creation and alignment skyrockets.
This is where DTF printing (Direct to Film) and hybrid printing step in as smarter alternatives. They don’t require individual screens, so adding more colors doesn’t increase setup time or cost. You can print full-color artwork – including detailed logos and shading – without worrying about separations or registration.
And if you’re printing multiple SKUs or varying graphics across your apparel range, screen printing quickly becomes inefficient. Imagine making new screens for every version. That’s time and money lost.
Screen Printing:
Hybrid Printing:
Fast Turnaround Needs a Different Approach
In today’s market, speed is a competitive advantage. Brands need flexibility to restock bestsellers, fulfill rush orders, or respond to viral trends. The traditional screen printing setup doesn’t support that kind of agility.
DTF printing and hybrid methods can start production almost immediately. Once your design is ready, the process is streamlined—print, powder, press. This makes it ideal for short runs, fast restocks, or test collections. The lack of setup time makes it both faster and more cost-effective for time-sensitive orders.
Even for bulk runs, the time saved on setup often balances out the slightly higher cost per piece, especially when you factor in labor, revisions, and missed deadlines.
Hybrid Printing: The Best of Both Worlds
At In-Credible, we work with many brands that need the quality of screen printing but the flexibility of digital. That’s where hybrid printing becomes the go-to solution.
With hybrid production, we combine screen bases (for solid areas or white ink underlays) with DTF or digital overlays to bring your graphics to life. This method reduces screen count, shortens setup, and improves efficiency – especially on medium to large orders with complex visuals.
For example, if your design includes a full-color graphic over a dark garment, screen printing alone would require multiple layers and alignment. A hybrid approach, on the other hand, prints the white base using screen printing and the rest using DTF. This keeps quality high while reducing waste and cost.
What This Means for Brands
If you’re ordering bulk custom apparel, it’s no longer enough to assume screen printing is your best bet. You need to ask deeper questions:
- How many colors are in my design?
- How quickly do I need these produced?
- Are the graphics consistent across all SKUs, or are there variations?
- Do I need reorders or short runs in the future?
When you factor in these variables, DTF printing and hybrid printing often outperform screen printing on cost, time, and flexibility. This is especially true for ecommerce sellers, fashion startups, and event merch lines that need to move fast and stand out visually.
A Smarter Printing Partner Makes All the Difference
At In-Credible, we help brands across Vietnam and internationally choose the right production method for each project. With more than 11 years in the garment printing industry, we’ve seen firsthand that there’s no one-size-fits-all answer. That’s why we offer screen printing, DTF, sublimation, DTG, and hybrid solutions under one roof.
We take the time to review your artwork, budget, and production goals before recommending a method. For some clients, that means classic screen printing. For others, it’s a hybrid approach that offers the speed and visual punch they need to grow.
Our production team in Ho Chi Minh City uses industry-leading machinery and streamlined workflows to deliver quality at scale. Whether you’re producing 200 or 20,000 pieces, we provide consistency, transparency, and flexible support.
Final Thoughts
Screen printing is still a valuable and high-quality technique, especially for simple, large-scale designs. But it’s no longer the universal low-cost option it once was. For multi-color graphics, time-sensitive projects, or flexible product lines, DTF printing and hybrid printing often deliver better results with less risk.
As a brand, the smartest move is to work with a partner who can offer multiple options – and who understands that every project is different.
Need help choosing the right printing method for your bulk order? Talk to the In-Credible team today and let us guide you toward the best solution for your brand.