Last month, we looked at various printing methods and how they compare. All the options and industry jargon can be enough to make your head spin. Some of these methods just aren’t used that often, and are easily mixed up. The inconsistent results of internet searches don’t make it any clearer. If you aren’t working with a professional, you may end up with something other than what you wanted. When used effectively, these imprint techniques can really make your piece pop (along with your brand).
So, once again, we’re looking at print methods and diving in a bit deeper into how the process works and under what circumstances it might be the perfect choice for your project.
Screen Printing
Process:
Fine mesh screens are created for each color in a design. Ink is then pressed through the screen onto the fabric. The printed fabric is dried, often with heat, to set the ink.
Quality:
Produces long-lasting prints that can withstand repeated washing
High quality, durable and vibrant color output, ideal for bold, solid colors
Best suited for simple designs with fewer colors
Versatile method used for apparel, signage, and other promotional items, most commonly fabric
Speed:
Longer setup time on multi-color designs
Once set up, screen printing is fast and efficient
Well-suited for larger production runs
Cost:
Higher setup costs due to the creation of individual screens for each color
Lower per-unit cost for large quantities
Direct-to-Garment (DTG) a.k.a. Digital Printing
Process:
Works like a regular inkjet printer, applying the ink directly to the fabric
Quality:
High-quality prints with a soft feel
Ideal for complex designs and multiple colors
Color vibrancy can vary with fabric type
Speed:
Quick setup and production time
Cost:
Lower setup costs, affordable for small quantities and custom orders
Higher per-unit cost for large orders
Pad Printing
Process:
Uses a soft silicon pad that easily adapts to 3D and irregular shapes
Printing plate is laser engraved with design and ink is applied to the plate
Silicon pad collects the ink and applies the ink to the item by machine
Quality:
Crisp, high quality finish
Compatible with most materials including highly chemical-resistant surfaces
Compatible with irregular shapes including small, fragile materials
Speed:
Setup time is quick
Printing is slower
Great for multi-color designs
Cost:
Very cost effective
Heat Transfer (including Vinyl and Sublimation)
Process:
Vinyl: Design is cut from colored sheets of vinyl and applied with heat
Sublimation: Design is printed with special ink that turns into gas and infuses into polyester fabric
Heat Transfer Paper: Design is printed on special paper and transferred to fabric using heat and pressure
Quality:
Vinyl: Durable and vibrant, good for simple designs
Sublimation: Excellent for full-color designs but limited to polyester or polymer-coated items
Heat Transfer Paper: Can crack or peel over time, especially if not properly applied
Speed:
Relatively quick setup and production time
Ideal for small to medium quantities
Cost:
Moderate setup costs
Cost-effective for short runs and custom designs
Patches
Process:
Patches are created in custom shapes and sizes using a variety of imprint methods.
Embroidered patches have finished or merrowed edges
Printed patches are decorated using DTG printing
Leather patches are cut to shape and imprinted via laser debossing.
Vinyl patches use liquid PVC rubber poured into a custom metal mold, one layer at a time, and heated to dry.
Patches are fully standalone decorations that can be created in bulk and held for expedited future use.
They can be affixed to varied products on demand via heat press, sewing and more. Quality:
Flexible, versatile and durable
Custom shapes and sizes
Impressive 3D tactile design
Use the same patch on multiple products
Small details may be difficult to capture
Classy look for made-to-order products Speed:
Custom plates and stitching mean longer setup time
Quick reorders and custom in-stock use Cost:
High setup costs
Cost effective for medium to large orders
Custom molds, labor, and higher order minimums
Best for medium and large quantities
Embroidery and Appliqué
Process:
A digitized design is created to guide the embroidery machine
Embroidery: Uses thread to stitch the design onto the garment
Appliqué a.k.a. Tackle Twill: Adds pieces of fabric cut into shapes and sewn onto the garment
Laser appliqué cuts the fabric to shape via laser after it is sewn onto the garment Quality:
High durability and unique, 3D textured look
May not work for detailed and intricate designs
Best for logos and simple designs with distinct shapes
Typically used for special, high-end items Speed:
Slower than printing methods due to the sewing process
Larger or more detailed designs take longer to produce Cost:
Higher cost per unit due to labor and materials
Cost-effective for simple designs
Laser Engraving, Etching, and Marking
Process:
Laser marking, etching, and engraving are all processes that create your design by removing part of the material with a laser. The main difference between them is how much of the material’s surface is removed:
Laser marking: Removes just the surface of the material, changing the color
Laser etching: Melts the surface of the material, leaving deeper, textured markings
Laser engraving: Vaporizes the material, creating crisp, deep marks Quality:
High-end look
Works on metal, wood, and certain synthetic materials like plastic and fleece
Subtle design less vibrant than other methods Speed:
Quick setup and production time Cost:
Moderate cost, varying with complexity and material
Economical for medium or large quantities
Debossing / Embossing
Process:
Uses heated metal plates to press or imprint the design into the product. Designs can be further enhanced by adding foil or ink.
Debossing: A single metal plate stamps the design into the front of the material.
Embossing: Two metal plates push the design from underneath, creating a raised effect.
Blind debossing/embossing refers to using no ink or metallic foil, producing a more subtle effect. Quality:
Special and unique, high-end appearance
Embossing: Preferable for paper products due to finer detail capability.
Debossing: Often used for materials like fleece or leather.
Not suitable for plastics or materials that can’t withstand high heat and pressure Speed:
More complex and time-consuming setup and preparation than flat-surface printing.
Slower production due to detailed process. Cost:
More expensive than other printing methods, due to the extra time involved in the process
Best for medium to large quantities
Offset Printing a.k.a. Lithography
Process:
Uses a rubber blanket to print newspapers, magazines, brochures, books, and stationery
Printing plate is laser engraved with design and ink is applied to the plate
Rubber blanket collects the ink and applies the ink to the item by machine Quality:
Sharp, clean images and text
Excellent color reproduction using CMYK color model
Compatible with most flat materials including paper, cardboard, and plastic Speed:
Setup time is slower
Printing is quick Cost:
Cost effective for large runs
We’re the Experts. Let us help.
Each imprint method has its advantages and is suited for different types of designs, materials, quantities, and budgets. The choice depends on the specific needs of the project, including the desired look, feel, durability, and production timeline. Our team can help you choose the perfect, high-quality item and imprint to meet your needs.