DTF or referral.
We do not run traditional screen-print orders below 25 pieces. For a small full-color order, DTF is usually the first option we evaluate. If traditional screen printing is specifically required, we can refer the job.
See DTF →
SCREEN PRINTING • DTF • COLOR SEPARATIONS
PRINTING THAT STARTS
PRINTING THAT STARTS
WITH THE RIGHT PROCESS.
We build the artwork, prep the production files and choose the print method around the actual job—not around one machine. Traditional screen printing starts at 25 pieces. At 50+, the economics usually get much better.
25+screen print minimum
50+better-value production tier
DTFfull-color flexible runs
PREPRESSseparations + production art
Choose the route that makes money and makes sense.
Quantity matters, but so do ink colors, design detail, garment type, placement and deadline. Use this as a fast starting point; final production is quoted after we inspect the artwork.
Screen print eligible.
This is our entry tier for screen printing. Simple 1–2 color art is the strongest fit. Complex multi-color art may still be more cost-effective as DTF once screens, setup and labor are considered.
Screen-print details →Better screen-print value.
Setup costs are spread over more garments, so this is where traditional screen printing starts becoming much more attractive—especially for repeat logos, school shirts and company apparel.
See cost factors →Volume production.
Large repeat runs usually create the strongest unit economics. We can plan garments, print locations, separations, underbases and reorders around a production-first workflow.
Request volume quote →TRADITIONAL SCREEN PRINTINGBuilt for repeatable
Built for repeatable
production.
Screen printing pushes ink through a prepared mesh stencil. Each production color normally requires its own screen, which is why quantity and color count directly affect cost.
Best for25+ pieces, repeat logos, teams, uniforms, events, branded apparel.
Strongest value50+ pieces with controlled color count and consistent placement.
Not acceptedTraditional screen-print runs below 25 pieces.
What changes priceGarment, colors, locations, screens, specialty inks, names/numbers, deadline and shipping.
DIRECT TO FILM / DTFFull color without
Full color without
a screen per color.
DTF prints artwork to transfer film, applies adhesive powder and heat-transfers the finished image to the garment. That makes detailed, multi-color graphics practical when screen setup would be excessive.
Best forSmall runs, detailed full-color art, photographs, gradients, many colors and mixed order sizes.
QuantityFlexible. Unlike our screen-print service, DTF is not locked to a 25-piece screen minimum.
Cost driverPrinted image size matters more than the number of colors.
ImportantPolyester and heavily dyed garments may need blocker / anti-migration solutions.
OUR PREPRESS SPECIALTYColor separations that are built
Color separations that are built
for the press.
A pretty design file is not automatically a printable screen-print file. We separate artwork into production channels, plan underbases and halftones, and organize files so the printer knows what each screen is supposed to do.
Spot Color
One channel for each solid ink color. Best for logos, text, mascots and clean illustrated graphics.
Typical: 1–6 colorsCMYK Process
Cyan, magenta, yellow and black halftones combine visually to reproduce full-color art, usually on light garments.
Typical: 4 process colorsSimulated Process
Custom spot inks and halftones recreate photographic or highly detailed art—especially on dark garments.
Typical: 6–10 colorsIndex Color
Square-dot patterns use a controlled palette without traditional halftone dot sizes. Useful for certain detailed graphics and difficult presses.
Typical: 6–10 colorsUnderbase + Highlight
Dark shirts often need a white foundation under the color. A separate highlight white can restore bright details and contrast.
Built around garment colorProduction File Cleanup
Vector redraws, trapping, choke/spread, registration marks, channel naming, sizing and final press-ready output.
Quoted by complexityCOLOR SEPARATION PRICING$15–$30Typical simple / standard jobs
ADVANCED / SIM PROCESS$50–$85+Typical market range for complex work
AIRBRUSH SOME STUFFQuoted by jobWe review art, garment + press needs first
SEND ART FOR A SEPARATION QUOTE →ARTWORK NOT READY?
SEE GRAPHIC DESIGN →We can build the design before we print it.
Logo cleanup, vector rebuilding, custom apparel graphics, print-ready production art and color separation can all be handled before the job reaches the press.
Screen printing has setup costs.
Quantity spreads them out.
The total job is not simply “shirt price × quantity.” Screens, films, press setup, ink changes, underbases and production time happen before the first finished shirt. More pieces spread those fixed costs farther.
QuantityOur routeBest fitValue
1–24DTF / referralFull color, smaller projectsScreen print not offered
25–49Screen print eligibleSimple colors / established artEntry production tier
50–99Preferred screen printBusiness, school, event, teamBetter unit economics
100+Volume quoteRepeat programs + merchandiseBest production efficiency
Each screen-print color normally means another screen and another press pass.
Front, back, sleeve and pocket are separate production locations.
T-shirt, hoodie, performance polyester, safety shirt and premium blank all change cost.
White underbase and flash steps may be required for opacity.
Cleanup, redraw, separations and difficult low-resolution files add prepress time.
Rush work is subject to capacity and can add cost.
Market reference: Published 2026 contract-printer pricing shows decoration-only one-color screen printing dropping as quantity increases, while extra colors add cost. Wholesale transfer suppliers show the same volume pattern. These are industry references—not your final Airbrush Some Stuff quote.
SCREEN PRINTING LANGUAGEKnow what the printer
Know what the printer
is talking about.
These are the terms that matter when artwork moves from the computer to the press.
Color Separation
Splitting artwork into individual ink channels so each color can be burned onto its own screen.
Spot Color
A specific solid ink color printed from its own screen—ideal for logos and clean graphics.
Underbase
A white ink foundation printed below colors on dark garments so the colors stay bright.
Flash
A short heat step between print layers that partially cures ink before the next color is printed.
Registration
Aligning multiple screens so every printed color lands in the correct position.
Halftone
Tiny dots used to simulate shades, gradients and photographic detail with a limited number of inks.
Mesh Count
The number of threads per inch in a screen. Fine detail and heavy ink deposits require different meshes.
Choke / Spread
Slightly shrinking or expanding a color edge so registration movement does not create visible gaps.
Simulated Process
Spot-color halftones chosen specifically to reproduce detailed/full-color art, especially on dark shirts.
CMYK
Cyan, magenta, yellow and black process printing used to visually mix a wide range of colors.
Index Separation
A separation method that uses same-size square dots instead of conventional halftone dots.
Plastisol
Common screen-print ink that sits strongly on fabric and cures with heat.
Water-Based Ink
Ink designed to soak more into fibers for a softer feel; production requirements differ from plastisol.
Blocker
A migration-resistant layer used on certain polyester/dyed garments to reduce dye bleeding into the print.
Gang Sheet
Multiple designs arranged on one transfer sheet to use the printable area efficiently.
Print Location
Each separate area printed—front, back, left chest, sleeve, etc.—is its own production location.
SEND BETTER ART • GET BETTER PRINTS
Artwork checklist.
Send the cleanest source you have. If it is not ready, we can rebuild or prepare it.
- Best: AI, EPS, SVG, vector PDF, layered PSD/TIFF.
- Usable: transparent PNG at final size, preferably 300 DPI.
- Tell us: garment color, quantity, print width, locations and deadline.
- Brand colors: include Pantone/PMS values if exact matching matters.
- Avoid: screenshots, tiny social-media images and heavily compressed JPGs when possible.
BUSINESS + TEAM APPAREL
EXPLORE BUSINESS SERVICES →Need the design, shirts and repeat ordering?
We can organize branded apparel as part of a broader business package—logos, graphics, uniforms, murals, vehicle visuals and websites.
Before you send the job.
Why is your screen-print minimum 25 pieces?
Traditional screen printing has fixed setup work—art prep, film, screens, registration, ink setup and press time. Below 25 pieces, that setup can make the job too expensive to run profitably. DTF is often a better solution for smaller jobs.
Will 50 shirts cost less per shirt than 25?
Usually, yes. The final quote still depends on garment, colors and locations, but the same setup is spread over twice as many pieces.
Can I bring my own shirts?
Ask before purchasing them. Customer-supplied garments can introduce fabric, coating, size and replacement issues. We need to confirm the garment is suitable for the selected production method.
Can you separate artwork for another screen printer?
Yes. Color separation and production artwork can be quoted as a stand-alone prepress service.
Is DTF cheaper than screen printing?
Sometimes. DTF avoids a screen for every color and is excellent for detailed full-color art. At higher quantities with simpler artwork, screen printing can become more economical. We compare the actual job rather than forcing one method.
Do you print fewer than 25 with traditional screens?
No. Our traditional screen-print minimum is 25 pieces. We can offer DTF where it makes sense or refer a screen-print job that must stay below the minimum.
READY TO PRICE THE REAL JOB?Send the quantity, artwork, garment,
Send the quantity, artwork, garment,
locations and deadline.
We will decide whether screen print, DTF or a mixed production route makes the most sense and quote it accordingly.