Screen Printing vs. Embroidery vs. DTF: Which Decoration Method Is Right for You? Canadian Custom Apparel

Screen Printing vs. Embroidery vs. DTF: Which
Decoration Method Is Right for You?

By Canadian Custom Apparel | Concord, Vaughan, Ontario | canadiancustomapparel.com

If you're ordering custom apparel for the first time, one of the first questions you'll face is: which decoration method should I use? Screenprinting, embroidery, and DTF (direct-to-film) printing are the three most common methods used by custom apparel companies across Toronto and the GTA — and each one has clear strengths and weaknesses depending on your order.

The right decoration method depends on your design, your quantity, your garment type, and your budget. This guide breaks down all three methods side by side so you can make a confident decision.The right decoration method depends on your design, your quantity, your garment type, and your budget. This guide breaks down all three methods side by side so you can make a confident decision.

Quick Comparison

Screen printing — the bulk order workhorse

Screen printing has been the dominant decoration method in the custom apparel industry for decades. When you need a large run of the same design at the lowest possible cost per piece, screen printing is almost always the answer.

How screen printing works

Each colour in your design gets its own screen — a mesh frame with a stencil of that colour. Ink is pushed through the screen onto the garment, one colour at a time. CCA prints up to 12 colours and charges no setup fees, making it accessible for designs that other suppliers would charge heavily to set up.

When screen printing is the right choice

• You're ordering 24 or more pieces — that's CCA's minimum for screen printing
• Your design has up to 12 colours
• You want the lowest cost per piece on a large run
• You're printing on t-shirts, hoodies, crewnecks, tote bags, or similar garments
• You want specialty ink effects like metallic, glitter, puff, or reflective

Screen printing limitations

• Minimum order of 24 pieces — not suitable for single pieces or very small quantities
• Not ideal for designs with fine photographic gradients
• Requires flat or semi-flat surfaces — not suitable for heavily structured garments
• Colour matching requires Pantone codes for guaranteed accuracy

Screen printing pricing at CCA

CCA charges no setup fees for screen printing. Pricing is based on the number of ink colours and total quantity. Bulk screen printed t shirts can start as low as $7/piece for large orders. The more pieces you order, the lower the cost per piece.

Screen printing is the right choice if you're ordering 24+ pieces with a design using up to 12 colours and want the best value per piece. No setup fees at CCA.

Embroidery — the premium corporate choice

Embroidery is the decoration method of choice for corporate uniforms, professional workwear, and any situation where you want your brand to look polished and premium. There's a reason every serious corporate uniform program in the GTA uses embroidery — it conveys quality in a way that printed methods simply can't match.

How embroidery works

Embroidery uses a computerized machine to stitch your design directly into the fabric using
thread. Your artwork is first digitized — converted into a stitch file — for a one-time setup fee.
The result is a textured, three-dimensional decoration that's part of the garment itself.

When embroidery is the right choice

• You need corporate uniforms, polo shirts, or staff workwear
• You want a premium, professional look on hats, jackets, vests, or outerwear
• You're ordering any quantity — no minimum at CCA
• Durability is critical — embroidered logos outlast most print methods
• You want a high-end look for corporate gifts or branded merchandise

Embroidery limitations

• One-time digitizing fee to convert your artwork to a stitch file
• Not suitable for highly detailed designs with very thin lines or tiny text
• Photographic or gradient artwork can't be reproduced in thread
• Works best for logos under approximately 4 inches wide

Embroidery pricing at CCA

Embroidery pricing is based on stitch count. A simple left-chest logo on a polo shirt typically runs $30–$65 per piece depending on the garment and stitch count. The one-time digitizing fee ,is charged upfront and reused on all future orders of the same design.

Embroidery is the right choice for corporate uniforms, polo shirts, hats, and workwear.
No minimum order at CCA — you can embroider a single piece.

DTF Printing — the versatile newcomer

Direct-to-film (DTF) printing is the newest of the three main decoration methods and is rapidly becoming the most popular choice for small orders, complex designs, and situations where screen printing or embroidery aren't practical.

How DTF printing works

DTF prints your design onto a special film using full-colour inkjet ink, including a white ink layer. The printed film is then transferred to the garment using a heat press. Because the design is printed onto film first, DTF works on cotton, polyester, nylon, blends, and performance wear.

When DTF is the right choice

• You need fewer than 24 pieces — below screen printing's minimum
• Your design has many colours, gradients, or photographic elements
• You need to print on polyester, nylon, or performance fabrics
• You want full-colour printing with no setup fees
• You need fine detail, thin lines, or small text that embroidery can't handle

DTF limitations

• Higher per-piece cost than screen printing on large quantities
• Slightly different feel compared to screen printing

• Not as textured or premium-looking as embroidery for corporate applications
• Requires proper washing care — cold water, no bleach, no high heat

DTF pricing at CCA

DTF has no setup fees and no minimums. Single-piece DTF orders start at $20 for a custom t-shirt, $35 for a crewneck, and $40 for a hoodie. Volume discounts apply at higher quantities.

DTF is the right choice when you need fewer than 24 pieces, a complex full-colour design, or printing on polyester and performance fabrics. No setup fees, no minimums.

Which method wins for each use case?

Corporate uniforms and workwear

Winner: Embroidery. For polo shirts, jackets, vests, and professional workwear, embroidery is
the clear choice. The textured, premium look signals quality that printed methods can't match.

Event t-shirts and bulk promotional runs

Winner: Screen printing. For 24+ pieces of the same design — corporate events, charity runs, team building — screen printing delivers the best value per piece with no setup fees at CCA.

Single piece or fewer than 24 pieces

Winner: DTF. No setup fees, no minimums, full colour. Whether you need one custom hoodie or 20 t-shirts for a small team, DTF is the most practical choice under the 24-piece screen printing minimum.

Sports team jerseys

Winner: Sublimation or DTF. Full-colour team jerseys with player names and numbers are typically done via sublimation or DTF. Jersey orders at CCA typically take 5–6 weeks.

Hats and structured headwear

Winner: Embroidery. The curved surface of a hat makes flat printing methods difficult. Embroidery is almost always the right choice for caps and structured headwear.

Full colour or photographic designs

Winner: DTF. If your design has gradients, shadows, or photographic elements, DTF is the only practical choice. Screen printing handles up to 12 colours, but not continuous-tone photographic artwork.

Polyester and performance fabrics

Winner: DTF. If you're printing on athletic wear, moisture-wicking shirts, or performance jackets, DTF is the most reliable choice.

Frequently asked questions

What is the minimum order for screen printing at CCA?

The minimum order for screen printing at CCA is 24 pieces. For orders under 24 pieces, DTF printing is the recommended alternative — it has no minimum, no setup fees, and handles any design at any quantity.

How many colours can CCA screen print?

CCA screen prints up to 12 colours with no setup fees. Most designs fall well within this range. For designs requiring more than 12 colours or photographic gradients, DTF printing is the better choice.

Does CCA charge setup fees for screen printing?

No — CCA does not charge setup fees for screen printing. Pricing is based on the number of ink colours and total quantity only.

Which lasts longer — screen printing, embroidery, or DTF?

All three are durable when cared for properly. Embroidery is generally the most durable — thread doesn't fade or crack. Screen printing with plastisol ink is extremely durable on cotton. DTF is highly durable but requires cold water washing and no high heat.

Can I get a single custom t-shirt in Toronto

Yes — CCA offers single-piece DTF printed t-shirts starting at $20 with no minimum order and no setup fees. Order online at canadiancustomapparel.com or call (905) 518-0660.

Where can I get custom screen printing in Vaughan or Toronto?

Canadian Custom Apparel is located at 82 Corstate Ave, Concord, ON L4K 4X2 — in Vaughan, just north of Toronto. We offer screen printing, embroidery, and DTF printing for businesses and organizations across the GTA. Order online or call (905) 518-0660.

Get a custom quote at canadiancustomapparel.com or call (905) 518-0660.

Canadian Custom Apparel — 82 Corstate Ave, Concord, ON L4K 4X2 — Open Mon–Fri
10am–6pm — Free shipping on orders over $400 across Canada.