DTG (direct-to-garment) printing for corporate apparel in Cyprus | Merch Cyprus
When DTG is the right answer — short runs, photographic images and cotton-rich garments, with no screens and no setup.
DTG in a corporate apparel context
Direct-to-garment (DTG) printing uses water-based ink jetted directly onto a pre-treated garment from a print head that moves across the fabric. The image is cured with heat and produces a soft, vibrant print that is integrated into the cotton fibres. DTG is the right answer for short runs (under 100 pieces), full-colour images, photographic prints and complex designs on cotton-rich fabrics.
How DTG works
The DTG process has three steps: pre-treat the garment, print the image directly onto the fabric, cure the print with heat.
Pre-treatment: a liquid pre-treatment is applied to the print area of the garment using a spray or a roller. The pre-treatment contains a chemical that helps the water-based ink bond to the cotton fibres and prevents the ink from soaking into the fabric. For dark garments, a white pre-treatment is applied as an underbase.
Printing: the garment is loaded onto a platen that holds it flat. The print head moves across the fabric, jetting micro-droplets of ink onto the pre-treated area. The print head is typically a piezoelectric inkjet head with thousands of nozzles. The print resolution is 1,440 dpi native.
Curing: the printed garment is cured in a heat press or a conveyor dryer at 160–180°C for 90–180 seconds. The heat evaporates the water in the ink and bonds the pigment to the fabric fibres.
Compatible substrates
DTG works best on cotton and cotton-rich blends. Polyester and synthetic fabrics require special inks or alternative techniques.
100% cotton: the ideal DTG substrate. The pre-treatment bonds the ink to the cotton fibres and the print is soft, vibrant and durable for 50+ wash cycles.
Cotton-rich blends (80%+ cotton): DTG works well. The synthetic content is small enough not to interfere with the ink bonding.
Cotton-polyester blends (50/50 to 65/35): DTG works but the print is slightly less vibrant and the durability is reduced (30–50 wash cycles). The synthetic fibres do not absorb the water-based ink as well as cotton.
Polyester and synthetics: not compatible with standard DTG inks. The water-based ink beads on the synthetic fibres and does not bond. For polyester, we use dye sublimation. For polyester blends, DTF or screen printing with polyester inks.
Dark garments: DTG handles dark fabrics but requires a white underbase layer. The underbase adds 30–40% to the print time and increases the per-piece cost. DTF handles dark fabrics without the underbase step.
DTG vs. DTF vs. screen printing vs. sublimation
Four techniques for fabric printing. Choosing the right one is a question of volume, fabric and design.
DTG: best for 1–100 pieces on cotton-rich fabrics with full-colour images. Soft feel, photographic quality, no screens. Slower on dark fabrics (underbase needed).
DTF: best for 50–500 pieces on cotton, polyester and blends with full-colour images. Faster than DTG, works on more substrates, slightly less soft feel.
Screen printing: best for 500+ pieces with simple designs (1–4 colours). Most durable (100+ wash cycles), lowest per-piece cost at volume, but expensive setup for full-colour images.
Sublimation: best for 100% polyester with full-colour images. Print becomes part of the polyester fibres, very soft, very durable. Not compatible with cotton.
Cost and lead time
DTG is the most economic answer for short runs on cotton. The per-piece cost drops as the volume increases, but DTG never beats screen printing at high volume.
Setup cost: €20–€50 per design for the pre-treatment setup. No screens, no films, no plates. Lower than screen printing for full-colour designs.
Per-piece cost on light cotton: €1.50–€3.00 per piece depending on size. For a 50-piece run with a chest print on light cotton, the cost is €2.00–€2.50 per piece.
Per-piece cost on dark cotton: €2.50–€4.50 per piece because of the white underbase. For a 50-piece run with a chest print on dark cotton, the cost is €3.00–€4.00 per piece.
Production rate: 30–60 pieces per hour for light fabrics, 15–30 pieces per hour for dark fabrics (because of the underbase).
Lead time: 3–5 working days for the production run, 1–2 days for QC and packing. Total 5–10 working days from artwork approval to delivery.
MOQ: typically 25 pieces. For a single piece (one-off gift, prototype), we can run DTG at a higher per-piece price (typically 3–5x the standard price).
Limitations of DTG
DTG is not the right technique for every apparel programme. The list below is the practical reality.
Polyester and synthetics: not compatible. Use sublimation for 100% polyester, DTF for blends, screen printing for simple designs.
Very large prints: DTG platen sizes limit the print area. Standard platens handle A4-size prints. For larger prints (full front wrap), we need a larger platen and the per-piece cost increases.
Outdoor wear: DTG prints degrade in direct sunlight faster than screen prints. For uniforms worn outdoors daily, screen printing or embroidery is more durable.
Commercial laundering: DTG prints may degrade faster than screen prints under commercial laundering conditions (industrial detergents, high temperatures). For hospitality uniforms, screen printing or embroidery is recommended.
Very small text: text below 8 pt may not reproduce cleanly on DTG. The ink can spread on the fabric surface, blurring the text. For very small text, embroidery or screen printing is better.
When to choose DTG
Three scenarios where DTG is clearly the right answer.
First, one-off or short-run apparel (1–50 pieces) with full-colour images. Screen printing requires 4–6 screens for a full-colour image; DTF is overkill for very short runs. DTG is the right balance of cost and quality.
Second, photographic images on cotton T-shirts. Sublimation does not work on cotton; screen printing cannot reproduce photographs; DTF can but is slower. DTG is the right answer for photographic prints on cotton.
Third, prototype programmes and samples. For a design proof or a sample run, DTG produces a representative printed garment at a reasonable cost. The strike-off can then be approved before serial production.
Frequently asked questions
What is the minimum order for DTG?
25 pieces for standard pricing. For 1–10 pieces, we can run DTG at a higher per-piece price (typically 3–5x the standard). For 50–500 pieces, DTF is more economic. Above 500 pieces, screen printing is more economic.
Can DTG match Pantone colours?
Within ΔE 2.0 of the Pantone standard for most colours. DTG uses CMYK + white inks; some Pantone colours (especially metallics, fluorescents and certain spot colours) cannot be reproduced exactly. For critical Pantone matches, screen printing with Pantone-mixed inks is the right answer.
How durable is DTG?
50+ wash cycles on light cotton, 30–50 on dark cotton or cotton-polyester blends. The print is integrated into the fabric and remains soft. For longer durability, screen printing or embroidery is more durable.
Can DTG print on dark T-shirts?
Yes, with a white underbase layer. The underbase is printed first, then the colour image on top. The underbase adds 30–40% to the print time and increases the per-piece cost. For a more efficient dark-fabric solution, DTF is the right answer.
Is DTG environmentally friendly?
Yes. DTG uses water-based pigment inks (not plastisol or solvent), so the chemistry is more environmentally friendly. The pre-treatment is water-based and biodegradable. The energy consumption is lower than screen printing (no screen production, no ink mixing). For ESG-sensitive programmes, DTG on organic cotton is a credible combination.
Can DTG print on polyester?
Not with standard water-based inks. The ink beads on the synthetic fibres and does not bond. For polyester, use sublimation (100% polyester only) or DTF. For polyester blends, DTF or screen printing with polyester inks.
Is Corp-Merch a partner or official sponsor of any events or brands covered on this page?
No. Corp-Merch coordinates merchandise-side work in B2B programmes and is independent of event organisers and brand owners.
Request a quote
We come back with pricing in EUR, lead time and options for your project.