Silkscreen wins for high-volume runs (500+) with 1-3 spot colors on cotton. Wash durability 50+ cycles. Lowest per-unit cost at scale. Pantone match exact.
DTF wins for medium runs (50-500) with full-color complex designs across multiple substrates (cotton, polyester, blends, leather, denim). Hybrid digital+heat-press. Wash durability 30-50 cycles. MOQ 20+.
Break-even: ~200 units for cotton with 1-3 colors. Below 200 → DTF flexibility wins. Above 200 → silkscreen cost wins.
DTF advantages: print transfers can be batch-produced (print 100 transfers ahead of orders), full-color photo, multi-substrate without changing technique.
DTF disadvantages: ink texture is felt (slightly raised), transfer process adds 30s/item, lower durability than silkscreen, requires heat press operation per item.
Silkscreen advantages: best durability, lowest cost at scale, classic look.
Decision: Below 200 units OR multi-material → DTF. Above 200 cotton 1-3 colors → silkscreen.