DTF Printing vs Screen Printing: Which is Better for Activewear?
The Printing Method Debate: DTF vs Screen Printing
When it comes to creating custom activewear for your gym, fitness studio, or sportswear brand, the printing method you choose has a massive impact on quality, durability, and cost. Two of the most popular options are Direct-to-Film (DTF) printing and traditional screen printing, but they serve very different purposes.
At Fitprint, we specialise in DTF printing for activewear because it consistently delivers superior results for the fitness industry. But that doesn’t mean screen printing is without its merits. Let’s dive into a detailed comparison so you can make an informed decision for your next project.
What is DTF Printing?
DTF (Direct-to-Film) printing is a modern digital printing process where designs are printed onto a special film, coated with adhesive powder, and then heat-pressed onto fabric. Unlike older methods, DTF doesn’t require screens, plates, or colour separations.
The process works on virtually any fabric colour and type, which makes it particularly well-suited for the diverse materials used in custom activewear printing.
How DTF Printing Works
- Your design is printed in full colour onto a PET film using specialised DTF inks.
- A hot-melt adhesive powder is applied to the wet ink.
- The film is cured in an oven to set the adhesive.
- The transfer is heat-pressed onto the garment at high temperature and pressure.
- The film is peeled away, leaving a vibrant, durable print.
What is Screen Printing?
Screen printing is a traditional technique that’s been around for decades. It involves creating a stencil (or screen) for each colour in your design, then pushing ink through the mesh onto the fabric one colour at a time.
It’s a proven method that works brilliantly for large-volume, simple designs. However, it has notable limitations when it comes to activewear.
Head-to-Head Comparison
Colour and Detail
DTF wins. DTF printing handles unlimited colours, photographic images, gradients, and fine details without any additional cost. Screen printing requires a separate screen for each colour, which increases both setup time and expense. If your design features a complex logo with gradients or photorealistic elements, DTF is the clear choice.
Fabric Compatibility
DTF wins. This is where DTF truly shines for activewear. Screen printing can struggle with stretchy, moisture-wicking fabrics like polyester blends, spandex, and nylon, which are the backbone of fitness apparel. DTF transfers bond effectively with these technical fabrics, maintaining print integrity even when the garment stretches during intense workouts.
Feel and Hand
Close call. Modern DTF prints have a soft, flexible hand that moves with the fabric. Screen printing with water-based inks can also achieve a soft hand, but plastisol screen prints tend to feel thicker and more rigid. For activewear that needs to feel comfortable against the skin during training, DTF’s thin, flexible print layer is a major advantage.
Durability
Both perform well. Quality DTF prints withstand repeated washing and heavy use without cracking, peeling, or fading. Screen printing is also highly durable, particularly with plastisol inks. Both methods deliver gym-ready durability when executed properly.
Minimum Order Quantities
DTF wins. Because there’s no screen setup required, DTF printing is economically viable for small runs — even single units. Screen printing requires screens to be created for each design and colour, which means setup costs need to be spread across larger quantities (typically 25+ units minimum) to be cost-effective.
This makes DTF the ideal choice for custom gym apparel orders of any size, whether you’re printing 10 staff shirts or 500 member tees.
Cost
It depends on quantity. For small to medium runs (under 100 units), DTF is almost always more affordable because there are no setup fees. For very large runs (500+ of the same design), screen printing can become more cost-effective per unit due to its speed and efficiency at scale.
Production Speed
Screen printing for bulk; DTF for flexibility. Screen printing is faster for churning out hundreds of identical garments. DTF is faster for varied designs, small batches, and quick turnarounds because there’s no screen preparation involved.
Print on Dark Fabrics
Both handle it. DTF includes a white ink layer beneath the colour layer, ensuring vibrant prints on dark fabrics. Screen printing can also print on dark garments using an underbase layer of white ink, though this adds complexity and cost.
Why DTF is Better for Activewear
For the fitness industry specifically, DTF printing offers a combination of advantages that screen printing simply can’t match:
- Stretch performance: Prints flex with the fabric, which is critical for leggings, compression tops, and sports bras.
- All-over versatility: Works on polyester, nylon, spandex blends, and moisture-wicking fabrics without compromising print quality.
- No minimums: Perfect for gym owners who want to test designs before committing to large orders.
- Full-colour freedom: Your graphic designer can create without colour limitations, enabling more impactful branding.
- Quick turnarounds: Ideal for seasonal drops, event merchandise, and competition day gear.
When Screen Printing Still Makes Sense
Screen printing isn’t obsolete. It remains a solid choice in certain scenarios:
- Very large orders (500+ identical units) where per-unit cost is the priority.
- Simple, one-to-two colour designs on cotton-heavy fabrics.
- Specialty inks like metallic, glow-in-the-dark, or puff prints.
However, for the vast majority of custom activewear applications in the fitness industry, DTF delivers better results.
The Fitprint Recommendation
As Australia’s dedicated custom activewear printer, we’ve tested every method extensively. For gym owners, CrossFit boxes, fitness studios, and activewear brands, DTF printing is our recommended method. It handles the technical demands of performance fabrics, delivers stunning colour reproduction, and works for any order size.
Ready to see the difference DTF printing makes for your activewear? Place your order and experience premium custom printing built for the fitness industry.
Frequently Asked Questions
Does DTF printing crack or peel on activewear?
No. Quality DTF prints are designed to flex with stretchy fabrics. When applied correctly at the right temperature and pressure, they maintain their integrity through hundreds of washes and workouts.
Can I mix DTF and screen printing in one order?
It depends on the project. Some brands use screen printing for their cotton-blend basics and DTF for their performance pieces. Chat with us to work out the best approach for your range.
Which method is more eco-friendly?
DTF printing generally produces less waste because there are no screens to clean or reclaim, and no excess ink is wasted during setup. It’s a more efficient process overall, particularly for smaller runs.