How you choose to customise your workwear affects how successful the final product is. Embroidery, direct to film printing and screen printing are the most popular methods of customisation. But having so many options can be confusing.
What’s the difference between the three? And what’s best for your design? Each method has its strengths but to come to a decision you have to assess these key considerations: material choice, budget, design complexity, durability, and environmental impact.
This blog will explore the three most popular customisation methods, helping you choose the best way to personalise your workwear.
Embroidery places a logo on a garment by stitching it on. Your design is sent as a JPEG file. It is then digitised and stitched mechanically onto the final piece.
Direct to film, or DTF printing is a customisation technique that uses innovative printing technology involving ink and heat to transfer designs.
It provides high-resolution images with crisp lines and bold colours, ideal for large colourful designs.
Screen printing is when your design is separated into individual colours so a mesh screen can be created for each one. The ink is then forced through the mesh onto the garment. This process is repeated for each colour until the design is complete.
It’s ideal for bulk printing as the set-up is time consuming, but once ready, it has the ability to produce up to 500 items per hour. This makes it more cost effective even when the screen charges are added.
Cotton and polyester are widely used for personalised garments. This is typically 100% organic cotton, 100% recycled polyester or poly-cotton blends. They provide a smooth surface that’s able to absorb the ink well to deliver seamless embroidered or printed images that stand the test of time.
Embroidery is pretty universal in its material compatibility. It works well on cotton, polyester and poly-cotton blends. Because it’s stitched into the material, it’s not necessary for the shirt fibres to be able to absorb or stick to the ink.
Screen printing works well on cotton or majority cotton blend shirts. This is because cotton has naturally porous fibres so it absorbs ink well, making them ideal for the screen-printing process.
Polyester is better suited to DTF printing. Its synthetic, plastic-based fibres create a strong bond with the adhesive used in DTF printing techniques. Polyester also has moisture-wicking abilities. So not only is it great for vibrant design, it’s also high performance.
Choosing the most budget friendly design method largely depends on how many items you’re ordering.
For bulk orders, screen printing is the most cost-effective method. Producing up to 500 items an hour, screen printing is the go-to if you’re dressing an entire workforce.
Whereas for smaller orders or individual pieces, direct to film is the most affordable option. The less expensive set up and quick application reduces manufacturing costs.
Different customisation methods offer a different style to your workwear. If you're going for a simple design with a classic feel, embroidery is great for the job. It’s suitable for all materials and has great durability.
When your design is full of detail and crisp lines DTF is great for graphic prints. Maybe you’re producing a one off, completely unique design. DTF is perfect for high visual impact.
Screen printing is the perfect method for images with highly saturated, vibrant colours. The different screens are also good for producing detailed images.
Investing in workwear is a big cost for your business so you want it to last.
If longevity is a consideration for you then embroidery and screen printing are great for durability.
Screen printing applies thick layers of ink that are resistant to fade and peel off. Similarly embroidered designs won’t desaturate or crack.
Embroidery doesn’t require any chemical use like inks or solvents. It also produces less material waste than printing, so it’s considered the more environmentally conscious method.
Using water-based inks when opting for DTF printing is also an eco-friendly choice. Plus, it’s highly durable which further decreases its carbon footprint. Choosing long-lasting customisation means you won’t need to replace your workwear too soon. Even the greenest manufacturing process still releases carbon emissions through shipping and delivery.
Embroidery, screen printing and DTF printing all have strengths. It comes down to the material of choice, affordability, design, durability and environmental impact to decide what method is best suited for your workwear.
