Why More Colors Cost More in Screen Printing vs. DTF for LogoUp

When it comes to customizing apparel, many customers at LogoUp often wonder why the cost of adding more colors to their designs increases with screen printing, while the same does not apply to Direct to Film (DTF) printing. While both printing methods are highly effective for decorating apparel, the process behind each is vastly different, leading to varying costs, especially when it comes to using multiple colors.

In this blog, we’ll take an in-depth look at why more colors cost more in screen printing versus DTF, breaking down the technical, financial, and time-related aspects that impact the price difference.

Screen printing is one of the most established methods of apparel decoration and has been around for decades. It involves creating stencils, called screens, for each color in a design. The process requires precise preparation to ensure that the design is transferred accurately onto the fabric. The ink is applied layer by layer, with each color requiring its own screen and pass through the machine.

Why does this matter?

Each additional color in a screen-printed design requires its own screen and setup. This means that the more colors your design has, the more steps it takes to prepare and print. Let’s break this down a little further.

1. Screen Setup for Each Color

   The most significant reason why screen printing gets more expensive with additional colors is the screen setup process. Each color in your design needs its own screen. For a two-color design, two screens are required, one for each color. A five-color design would need five screens. Creating these screens requires time, expertise, and materials, all of which add to the cost.

   Moreover, after the screens are made, they need to be carefully aligned, a process known as registration. This ensures that all the colors line up perfectly when printed. The more colors involved, the more difficult and time-consuming the registration process becomes. This additional labor directly impacts the price of the finished product.

2. Increased Ink Usage

   Screen printing uses different inks for each color, and more colors mean more ink. Each color requires a separate application of ink, so every layer adds to the overall time, material, and cost. In designs with a wide range of colors, the ink cost can quickly add up, especially when specialty inks (such as metallics or fluorescents) are involved.

3. Time and Labor Costs

   Adding more colors increases the complexity of the printing process. More screens need to be set up and cleaned afterward. Additionally, the entire process needs to be done for each shirt, so a larger number of colors can slow down production significantly. All these factors require more time and labor, which increases the final price.

4. Waste and Testing

   Before a screen-printed item goes into full production, a test print is often run to ensure the colors are aligned correctly. The more colors in the design, the more challenging it is to ensure they all work together seamlessly, which may require multiple test prints. If something goes wrong during the printing process, the entire batch may need to be redone. This risk of waste further drives up the cost.

Unlike screen printing, Direct to Film (DTF) printing doesn’t require a screen for each color. Instead, DTF uses a digital process that prints designs onto a special film, which is then transferred onto the garment. The technology allows for high-resolution, full-color designs to be printed in a single step, regardless of the number of colors in the design.

Why is this beneficial?

With DTF, you can print an unlimited number of colors, gradients, and complex designs without worrying about the additional costs of setup or alignment. The design is printed in its entirety in one go, making the process much simpler and faster. This is the key reason why DTF does not charge extra for more colors, while screen printing does.

1. No Screens Needed

   As DTF printing is a digital process, there’s no need to create separate screens for each color. This eliminates the extra labor, time, and material costs associated with screen setup. You can have a design with one color or 20 colors, and the setup process remains the same. The machine prints all the colors in one pass, which saves both time and money.

2. Digital Ink Efficiency

   In DTF, ink usage is more efficient than in screen printing. DTF printers apply only the necessary amount of ink directly onto the film. There is no layering of inks or repeated passes over the fabric, which reduces ink waste. This is especially important in designs with multiple colors, where ink costs can become significant in screen printing. In DTF, the ink is calculated based on the design’s size, not the number of colors, keeping the cost consistent.

3. No Registration Required

   Since DTF prints the entire design in one pass, there’s no need for color registration. This eliminates the risk of misalignment, which can be a common issue in multi-color screen printing jobs. The elimination of registration means that DTF is much faster when printing intricate, multi-color designs, saving time and reducing the potential for mistakes.

4. Time and Labor Efficiency

   Because DTF doesn’t require screens or multiple passes for different colors, the process is far more efficient. It’s simply a matter of printing the design and transferring it onto the garment. For businesses like LogoUp that offer custom apparel, this efficiency allows for quicker turnaround times, especially for complex designs with numerous colors. The simplicity of the process also lowers labor costs, which can translate into more affordable pricing for customers.

Now that we’ve explored why screen printing costs more with additional colors, you might be wondering when it’s best to choose one method over the other.

• Screen Printing is ideal for:

  • Large orders of simple designs with only one or two colors

  • Designs that require special inks, such as metallic or puff inks

  • Projects where durability is the most important factor (screen prints can last through many washes)

• DTF Printing is ideal for:

  • Designs with multiple colors or gradients

  • Small to medium orders where setup time is limited

  • Complex designs with fine details that need to be printed accurately

  • Customers who want flexibility in the types of materials they can print on, such as polyester, cotton, or blends

The reason why more colors cost more in screen printing comes down to the nature of the process. Each additional color adds complexity, time, and materials to the setup, resulting in higher costs. DTF, on the other hand, offers a digital, one-step solution that doesn’t require additional labor for multi-color designs, keeping costs low and production times fast.

For businesses and customers at LogoUp, understanding the differences between these two methods can help in making informed decisions when selecting the best printing process for your needs. Whether you opt for screen printing for its durability or DTF for its vibrant, multi-color capabilities, knowing what drives the cost differences ensures you get the best value for your project.