You've got a 25-piece order, a 14-colour logo, and a deadline that doesn't care about screen setup costs. Sound familiar? If you've ever tried to get a small run of complex prints and winced at the quote, DTG printing was probably the answer your printer forgot to mention.

In this guide, we break down exactly how Direct to Garment (DTG) printing works, when it outperforms screen printing, and how Canadian businesses, from Oakville startups to national brands, are using it to produce custom apparel without the traditional constraints.

What Is DTG Printing?

Direct to Garment (DTG) printing is a digital inkjet printing process that applies water-based inks directly onto fabric. Think of it like a high-precision inkjet printer for your printer,  instead of paper, it prints on a stretched garment placed flat on the platen.

DTG was developed commercially in the early 2000s and has matured dramatically since then. Today's professional DTG machines, like the Kornit Atlas or Epson SureColor F3070 produce sharp, full-colour prints indistinguishable from top-end screen printing, but without the film separations, screen making, or ink-mixing overhead.

The result: print-on-demand capability with professional-grade output.

How DTG Works: Step by Step

1. Pre-treatment: Dark and coloured garments are sprayed with a pre-treatment solution (PTM) that helps ink bond to the fabric and produces a bright white base layer.
2. Loading: The garment is loaded flat onto the machine's platen and tensioned to prevent movement during printing.
3. Digital printing: The print head moves across the fabric, depositing CMYK inks (and white ink for dark garments) in precise layers based on the digital file.
4. Heat curing: The printed garment passes through a conveyor dryer or heat press at 160–180°C, bonding the inks permanently to the fibres.
5. Quality check: Each print is inspected for coverage, colour accuracy, and wash durability before shipping.

The entire process for a single shirt, from pre-treatment to cured print, takes roughly 3–8 minutes depending on design complexity. That's what makes DTG so well-suited to short runs and one-offs.

What DTG Printing Excels At

• Full-colour, photographic designs: Gradients, shadows, skin tones, and detailed artwork print exactly as they appear on screen — no colour limiting or halftone dots.
• Small quantities (1–50 pieces): No setup screens means no amortized setup cost. A one-shirt order is as viable as a fifty-shirt order.
• Complex artwork: Designs with dozens of colours or fine details that would require expensive multi-colour screen setups are straightforward with DTG.
• Rapid turnaround: Without screen production time, DTG orders can ship in 24–48 hours.
• Personalization: Names, numbers, or unique text per garment require no additional setup — ideal for events, team gear, or custom merchandise.

DTG vs Screen Printing: Head-to-Head Comparison

Here's an honest comparison across the metrics that matter most for Canadian businesses ordering custom apparel:

Prices are approximate CAD and vary by garment cost, quantity, and design complexity. Request a custom quote for accurate pricing for your order.

When DTG Wins: 5 Specific Scenarios

DTG isn't always the right call,  but in these five situations, it's the clear winner:

1. Small Orders Under 50 Pieces

Screen printing's setup cost is amortized over the run. At 10 pieces with a 4-colour design, you're paying $200+ in setup fees before a single shirt is printed. DTG has zero setup cost, making it far more economical for small runs. The break-even point varies but is typically between 50–100 pieces for simple designs.

2. Photographic and Gradient-Heavy Artwork

Got a design with a sunset, a detailed illustration, or skin tones? Screen printing simulates these with halftone dots and spot colours,  it requires skill and still doesn't match the original. DTG prints your file exactly as it appears, pixel for pixel. If colour accuracy is non-negotiable, DTG is the right choice.

3. Event Merchandise with Personalization

Running a 5K where every participant gets a shirt with their name? Ordering team jerseys where each needs a unique number? DTG handles per-unit personalization with no additional cost. Each print can be unique without any reprinting or re-setup.

4. Sampling and Proofing

Need to proof a design before committing to a 500-piece screen print run? DTG lets you produce one or two samples quickly and affordably, often within 24 hours. Many brands use DTG for sample approval before moving production to screen printing for large runs.

5. Limited-Edition or Short-Run Product Launches

Launching a capsule collection of 30 hoodies? Testing a new design before scaling? DTG lets you go to market fast without tying up capital in a large minimum order. If the design sells, you can always scale up with screen printing later.

When Screen Printing Wins

DTG is powerful, but screen printing remains the better choice in several scenarios:

• Large volume orders (200+ pieces): Once setup costs are spread across a large run, screen printing's per-unit cost drops significantly below DTG.
• Synthetic or blended fabrics: Polyester, nylon, and most performance fabrics don't absorb DTG inks well. Screen printing and DTF handle these substrates far better.
• Simple 1–3 colour logos: A clean one-colour corporate logo on 100 shirts is significantly cheaper with screen printing.
• Maximum wash durability requirements: Workwear, uniforms, or safety apparel worn daily benefits from screen printing's more durable plastisol inks.
• Specialty ink effects: Puff ink, metallic inks, and discharge printing are screen printing exclusives that DTG cannot replicate.

For a deeper look at how screen printing compares across decoration methods, read our guide on screen printing vs. embroidery: which is right for your brand.

What About DTF (Direct to Film)?

DTF (Direct to Film) printing has emerged as a strong complement to DTG, and it's worth understanding the difference. Instead of printing directly onto the garment, DTF prints onto a special film, applies a hot-melt adhesive powder, cures it, and then heat-transfers the finished film onto the garment.

DTF advantages over DTG:

• Works on virtually any fabric, cotton, polyester, nylon, blends, leather, even hats and bags
• No pre-treatment required
• Slightly more vibrant colours on dark garments in some applications

DTF disadvantages:

• Slightly raised feel compared to the soft hand of DTG
• Transfer edge can be visible on closer inspection
• Less breathable than DTG on cotton garments

At Only Custom Apparel, we offer both DTG and DTF and will recommend the best method based on your garment type, artwork, and quantity.

Fabric Requirements for DTG: Why 100% Cotton Matters

This is the most important technical factor to understand before ordering DTG prints. DTG inks are water-based and bond to natural fibres primarily cotton, through a combination of the pre-treatment solution and heat curing. The higher the cotton content, the better the ink absorption and the brighter the final print.

Fabric composition and expected DTG quality:

• 100% ring-spun cotton: Optimal — produces the brightest, most detailed prints with the best wash durability
• 100% combed cotton: Excellent — smooth surface for sharper detail
• 90/10 cotton-poly blend: Very good — minor quality reduction, still professional output
• 50/50 cotton-poly blend: Acceptable — noticeable reduction in vibrancy and coverage, especially on dark garments
• 100% polyester: Not recommended for DTG — inks don't bond properly; use DTF or sublimation instead

If you're sourcing your own garments for DTG printing, look for Gildan 64000, Bella+Canvas 3001, or AS Colour Staple tees as reliable, print-ready options available across Canada.

Pricing Guide for DTG in Canada

DTG pricing in Canada depends on four main variables: garment cost, garment colour (white/light vs. dark), print size, and quantity. Here's a realistic pricing framework:

Prices are estimates and exclude HST and shipping. Large print sizes (over 12" × 16") may incur additional charges. Get an exact quote for your specific project.

Important note on dark garments: Printing on black or dark-coloured shirts requires a white ink under-base layer, which adds print time, ink cost, and complexity. This is why dark garment DTG printing typically costs 20–40% more than the same design on a white shirt.

How to Order DTG Prints from Only Custom Apparel

Only Custom Apparel serves businesses and individuals across Oakville, the GTA, Niagara region, and all of Canada with professional DTG printing and a fast, straightforward ordering process:

1. Submit your quote request: Visit our custom apparel quote page and share your design file, garment preference, quantity, and timeline.
2. Design review: Our team checks your artwork for print readiness — resolution, colour mode, file format — and flags any issues before production.
3. Digital proof approval: We send a digital mock-up for your review. No production starts until you approve.
4. Production: Once approved, your order enters production. Most DTG orders ship within 3–5 business days.
5. Delivery across Canada: We ship nationwide. GTA and Niagara customers can also arrange local pickup in Oakville.

Not sure whether DTG, screen printing, or embroidery is right for your project? Our team will give you an honest recommendation based on your artwork, fabric, and budget — no upselling, just the best method for the job.

Frequently Asked Questions

How many washes does DTG printing last?

With proper care — cold water washing, inside-out, tumble dry low — professional DTG prints on quality cotton garments typically last 40–60 washes before any noticeable fading. Compared to traditional screen printing's 60+ washes, DTG is slightly behind but has improved dramatically in recent years with modern pre-treatment chemistry and ink formulations.

Can DTG print on hoodies, hats, and items other than t-shirts?

DTG works best on flat, smooth surfaces — standard t-shirts, sweatshirts (crew neck and hoodies with flat print areas), and tote bags. Curved surfaces like hats, structured caps, and cylindrical items cannot be DTG printed and are better served by embroidery or DTF transfers. Fleece-lined or textured hoodies may also affect print quality due to their surface irregularity.

What file format do I need for DTG printing?

The ideal file for DTG printing is a high-resolution PNG with a transparent background, minimum 300 DPI at print size, in sRGB colour mode. Vector files (AI, EPS, SVG) are also excellent as they can be rasterized at any resolution. Avoid low-resolution JPEGs or files with white backgrounds (which will print as a white rectangle). Our team will verify your file during the artwork check stage.

Is DTG printing available for rush orders in Canada?

Yes. At Only Custom Apparel, we offer expedited production for DTG orders. Rush orders (24–48 hour turnaround) are available for most standard orders and may incur an additional rush fee. Contact us directly for rush requests to confirm availability based on current production volume. We ship from Oakville, Ontario and use courier services that reach most Canadian cities within 1–3 business days.