Printing Planet UK
Screen printing is one of the oldest and most established methods of decorating fabric, and for the right project it remains unbeatable on cost, colour vibrancy and durability. But it is not the right method for every job. This guide from Printing Planet UK in Putney explains exactly how screen printing works, what it costs, when to use it and when to choose something else.
What Is Screen Printing?
Screen printing pushes ink through a fine mesh stencil – called a screen – directly onto the fabric. A separate screen is made for each colour in the design. A rubber squeegee drags ink across the screen, forcing it through the open mesh areas and onto the garment below.
The result is a layer of ink sitting on top of the fabric rather than being absorbed into it. This gives screen-printed designs their characteristic boldness: colours are fully opaque, edges are crisp and the ink does not fade or wash out the way dye-based prints can.
The Pros of Screen Printing
- Vibrant, opaque colour – inks sit on top of the fabric and remain bright on both light and dark garments
- Very durable – screen prints survive repeated washing without cracking or fading, especially when cured correctly
- Cost-effective at volume – once screens are made, each additional print costs very little
- Industry standard for promotional merchandise – the method used for most event t-shirts, sports kits and uniform runs
The Cons of Screen Printing
- Minimum quantities – setup costs mean screen printing rarely makes financial sense below 25 units
- Setup cost per colour – each additional colour requires a new screen, typically at £15-25 per screen
- Colour limit – most runs cap at six colours; beyond that, cost and complexity rise sharply
- No photographic gradients – solid areas of colour only; gradients and detailed shading require a technique called simulated process, which is complex and less common
Spot Colour vs Simulated Process
Spot colour screen printing uses solid, pre-mixed inks – the standard approach for logos, text and bold graphic designs. Each colour is a single flat tone.
Simulated process uses halftone dots of a limited set of ink colours to approximate the appearance of a full-colour photograph. It is more expensive, requires more screens and is less commonly offered. For photographic artwork, DTF or DTG will almost always produce a better result at lower cost.
Best Uses for Screen Printing
Screen printing is the right choice when:
- You need 50 or more pieces of the same design
- Your artwork is bold and uses five colours or fewer
- You are printing on standard cotton or cotton-blend t-shirts
- You want maximum print durability (sports kits, event uniforms, workwear)
- You need the lowest possible per-unit cost at high volume
It is not the right choice for:
- Small runs (under 25 pieces) where setup costs eat into the budget
- Full-colour photographs or complex gradients
- Orders with many different designs across a small number of shirts each
Design Tips for Screen Printing
Getting the most from screen printing starts with artwork built for the method:
- Bold, clean shapes – avoid thin lines under 1pt and tiny text below 8pt
- Limited colour palette – each extra colour adds a screen cost; try to achieve your design in three colours or fewer
- Avoid gradients – soft fades and shadows do not reproduce well in spot colour; use hard edges instead
- Check your traps – where two colours meet, ensure they overlap slightly (0.25mm) to prevent white gaps if the garment shifts between screens
- Supply vector artwork – EPS or AI files scale to any print size without quality loss; avoid relying on JPEG logos
Tip: If your brand uses a gradient in its logo, create a simplified flat-colour version specifically for screen printing. It will look sharper and cost less than attempting to reproduce the gradient with extra screens.
Screen Printing Cost Table
Prices below are for a standard front-chest print on a white or light cotton t-shirt, including one screen setup fee per colour:
| Quantity | 1 Colour | 2 Colours | 3 Colours |
|---|---|---|---|
| 25 | £8.50 each | £10.50 each | £12.50 each |
| 50 | £6.50 each | £8.00 each | £9.50 each |
| 100 | £5.00 each | £6.50 each | £7.50 each |
| 250 | £3.80 each | £5.00 each | £6.00 each |
Printing on dark garments requires a white underbase (counts as an extra colour/screen). Oversized prints (A2 or larger) and additional placements (back, sleeve) are quoted separately.
Screen vs DTF vs DTG: Quick Comparison
| Factor | Screen Printing | DTF | DTG |
|---|---|---|---|
| Minimum quantity | 25 | 1 | 1 |
| Full colour | Limited (simulated process) | Yes | Yes |
| Setup cost | Yes (per colour) | None | None |
| Best per-unit price at 100+ | Cheapest | Mid | Mid |
| Gradient reproduction | Poor | Excellent | Excellent |
| Fabric compatibility | Cotton and blends | Any fabric | Cotton |
| Durability | Excellent | Very good | Good |
When Printing Planet UK Recommends Screen Printing
At Printing Planet UK in Putney, we recommend screen printing when a customer needs 50 or more pieces of the same bold, limited-colour design and durability is a priority. It is the standard recommendation for promotional event t-shirts, school leavers hoodies (with a single-colour back print), sports club kits and charity run shirts.
For anything under 50 pieces, or any design with more than five colours, we will almost always steer you towards DTF or DTG for a better result at a lower total cost. Read our full method comparison guide to see how the methods compare side by side.
Want a screen printing quote for your project? Call Printing Planet UK on 020 3669 9854 or visit our Putney studio at SW15 3BD. We are happy to review your artwork and confirm whether screen printing is the best fit.
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