When it comes to creating custom t-shirts, uniforms, or teamwear, choosing the right shirt printing method is just as important as the design itself. Each technique, from traditional screen printing to high-tech sublimation or embroidery, offers different benefits in terms of durability, colour quality, fabric compatibility, and cost.
Whether you’re outfitting a school sports team, planning leavers' shirts, or launching branded apparel for your club, this guide breaks down the most popular types of shirt printing in Australia. We’ll explore the pros and cons of each method, what they’re best suited for, and how to choose the right one for your needs.
Most Popular Types of Shirt Printing
When it comes to creating high-quality custom uniforms, teamwear, or promo shirts, choosing the right printing method makes all the difference. Here are the most popular types of shirt printing used in Australia today, each with unique benefits depending on your design, budget, and fabric.
1. Screen Printing
Screen printing is a traditional and widely used printing method where ink is pushed through a mesh stencil (screen) onto the fabric. Each colour in the design requires a separate screen, making it ideal for bold, simple artwork.
Pros:
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Produces vibrant, long-lasting colours
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Highly cost-effective for large orders
- Suitable for cotton, polyester, and blends
- Excellent for bold logos and solid colour designs
Cons:
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High setup cost for small runs
- Not ideal for photographic or highly detailed prints
- Limited colour complexity due to layering process
Best For:
- School uniforms and PE kits
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Team jerseys for footy, netball, or cricket
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House colour shirts and event tees
2. Direct-to-Garment Printing (DTG)
DTG printing uses a specialised inkjet printer to apply ink directly onto the garment, much like printing on paper. It’s ideal for full-colour designs and detailed artwork, especially on 100% cotton garments.
Pros:
- No setup costs, ideal for short runs and one-offs
- Handles complex, full-colour graphics and gradients
- Produces a soft feel, with ink embedded in the fabric
- Eco-friendlier than plastisol-based screen prints
Cons:
- Works best on light-coloured cotton shirts
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Colours may appear duller on dark fabrics
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Slower for large bulk orders
Best For:
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Small quantity orders
- Detailed artwork or photo prints
- Personalised cotton shirts for events or leavers
3. Direct-to-Film Printing (DTF)
DTF printing involves printing your design onto a special film, which is then heat-pressed onto the fabric using an adhesive powder. It's a versatile and relatively new method that bridges the gap between DTG and vinyl printing.
Pros:
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Works on a wide range of fabrics (cotton, poly, blends)
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Excellent for fine detail, vibrant colours, and small batches
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No weeding or cutting like vinyl
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Better wash durability than some DTG prints
Cons:
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Slightly less breathable due to film layer
- Not yet as widely available as screen or DTG
- May feel slightly thicker on lightweight garments
Best For:
- Sports polos and team shirts
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Logo printing for school or corporate wear
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Poly/cotton blends and mixed-fibre activewear
4. Dye Sublimation / All-Over Printing (AOP)
Dye sublimation is a premium shirt printing method where heat and pressure are used to infuse ink directly into polyester fibres. All-over printing (AOP) takes it a step further, allowing seamless, full-coverage graphics across the entire garment, including sleeves and seams.
Pros:
- Extremely durable: the design won’t crack, peel, or fade
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Fully breathable, ideal for activewear
- Perfect for bold, full-colour designs and gradients
- Allows edge-to-edge printing for complete coverage
Cons:
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Only works on light-coloured polyester garments
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Not suitable for cotton or dark fabrics
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Slightly more complex production process
Best For:
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Custom teamwear and sublimated sports uniforms
- Netball dresses with intricate patterns
- School and club apparel with vibrant, all-over designs
5. Heat Transfer Vinyl Printing (HTV)
HTV involves cutting shapes or text from coloured vinyl sheets, which are then heat-pressed onto the shirt. It’s a popular method for personalisation, like player names and numbers on jerseys or leavers' tops.
Pros:
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Produces sharp, clean lines and solid colour blocks
- Great for one-off prints or small orders
- Excellent for adding names, numbers, or custom detail
- Works on a variety of fabrics including cotton and blends
Cons:
- Has a slightly heavier feel on the fabric
- Not ideal for high-detail or full-colour prints
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Labour-intensive for large or complex jobs
Best For:
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School leavers’ shirts and commemorative apparel
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PE uniforms with student names or house colours
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Individual teamwear customisation
6. Sublimation Printing
Sublimation printing is similar to dye sublimation but is typically used for smaller graphic areas, such as logos or panels, rather than all-over coverage. Like AOP, the ink becomes part of the fabric, making the print incredibly long-lasting and soft to the touch.
Pros:
- Vivid, photo-quality colours that never fade
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The print is embedded in the fabric, not on top
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Lightweight and completely breathable
- Suitable for multi-colour designs and gradients
Cons:
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Limited to white or light-coloured polyester garments
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Not compatible with cotton fabrics
- Doesn’t show well on dark materials
Best For:
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Sublimated polos and branded school sports shirts
- Event tees or promotional wear
- Custom sportswear with fine detail or gradients
7. Airbrushing
Airbrushing is a manual shirt printing technique where artists use a spray-paint airbrush tool to apply ink directly onto the fabric. This method allows for highly creative, one-of-a-kind designs, often seen in streetwear or promotional merchandise.
Pros:
- Highly customisable and artistic, perfect for unique pieces
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No setup required, good for one-offs or small batches
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Works on a variety of garments and surfaces
Cons:
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Time-consuming, not suited to bulk orders
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Less durable, colours can fade or crack over time
- Inconsistent results depending on the artist’s skill
Best For:
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Limited-edition merchandise
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Creative promotional shirts or fan gear
- One-off designs for special events
8. Plastisol Transfers
Plastisol transfers involve screen printing a design onto transfer paper, then applying it to a shirt using a heat press. It combines the look and feel of screen printing with the flexibility of heat application, great for complex, colourful designs in smaller quantities.
Pros:
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Sharp, detailed finish similar to screen prints
- Suitable for multi-colour artwork or intricate designs
- Allows for on-demand heat pressing, no full setup each time
Cons:
- Less breathable, can feel heavier on lightweight garments
- May crack or peel over time if not properly applied
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Slightly less durable than direct screen printing
Best For:
- Team logos on polos or jackets
- Branded hoodies and small-run merch
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Custom prints on-demand for events or promotions
9. Embroidery
Embroidery involves stitching thread directly into the fabric, creating a raised, textured design. It’s often used for logos, badges, or names on garments that need a polished, professional look.
Pros:
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Very durable, withstands washing and daily wear
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Premium appearance, adds value to branded clothing
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Ideal for small logos, initials, or monograms
Cons:
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Not suitable for large or detailed graphics
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Higher cost per item, especially for complex designs
- Slightly less comfortable on the inside of lighter garments
Best For:
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School polos and staff uniforms
- Corporate shirts, jackets, and caps
- Caps, bags, and accessories needing professional branding
Which T-Shirt Printing Method Should You Choose?
With so many types of shirt printing available, the best method really depends on your design, fabric, order size, and long-term goals. Below, we break down which techniques suit different needs, helping you make an informed choice whether you're ordering custom school uniforms, teamwear, or event shirts.
1. For High-Quality Prints
If your top priority is professional-quality printing with excellent visual impact, certain methods stand out for their premium finish and detail.
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Sublimation printing is a front-runner when working with polyester garments, offering vibrant colours and long-lasting results that won’t fade or peel.
- DTG (Direct-to-Garment) printing, on the other hand, is perfect for full-colour, detailed artwork on cotton shirts, producing a soft and natural feel.
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And if you’re after a polished, elevated appearance, especially for staff uniforms or polos, embroidery delivers a textured, premium look that screams quality and durability.
2. For Unlimited Colours & Complex Graphics
Not all printing techniques handle detailed or multi-colour artwork the same way. If your design includes photo-realistic elements, gradients, or numerous shades, you’ll want to go with DTG, Dye Sublimation, or DTF (Direct-to-Film).
- DTG is ideal for small-batch cotton shirts with rich, multi-layered visuals. Sublimation is perfect for polyester-based garments where the colour is infused into the fabric itself, creating bold and vibrant outcomes.
- DTF printing bridges the gap between flexibility and colour fidelity, offering a sharp finish across a variety of fabrics, including blends and darker materials.
3. For Fabric Compatibility (Cotton vs Polyester)
Shirt material plays a crucial role in determining print success.
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If you're printing on 100% cotton, methods like DTG and Screen Printing are your best bet. DTG provides detailed results with a soft touch, while screen printing offers a classic, bold finish that's ideal for teamwear and logos.
- For polyester or blended fabrics, opt for Sublimation, DTF, or Plastisol Transfers. These techniques work well with synthetics, offering durability and clarity without compromising the garment’s breathability or structure.
4. For Sustainable or Eco-Friendly Options
If sustainability is part of your brand or school’s values, there are shirt printing methods that align with eco-conscious goals.
- Water-based screen printing uses fewer chemicals and produces less waste than traditional plastisol inks.
- Sublimation printing is also considered more sustainable as it uses minimal water and doesn't rely on large-scale chemicals or adhesives.
Choosing the right method here not only supports the environment but also aligns your brand with responsible practices, something that’s increasingly important to students, parents, and consumers alike.
5. For Cost and Order Size
Budget and batch size are two of the most important practical considerations when selecting a shirt printing method.
- For smaller orders or one-off designs, such as custom names on school leavers’ shirts or personalised promotional wear, HTV (Heat Transfer Vinyl) and DTG are the most economical choices, thanks to their low setup costs.
- For large-volume orders, Screen Printing and Plastisol Transfers offer the best value per unit. While they involve more setup time, the cost savings scale quickly once you're printing dozens or hundreds of items, making them ideal for clubs, schools, or corporate teams.
6. For Quality and Longevity
If your printed garments are intended to endure frequent washing, heavy wear, or long-term use, like PE kits, teamwear, or workwear, you’ll want to invest in a method known for its staying power.
- Embroidery remains one of the most robust options, standing up to repeated laundering without fading or cracking.
- Sublimation is another excellent choice, especially for sportswear, as the print becomes part of the fabric and won't peel or fade over time.
- Screen Printing also offers strong durability when done professionally, particularly on cotton garments.
7. For Speed and Efficiency
When timing is tight, whether you're rushing to meet a school deadline, preparing for an event, or launching a fast campaign, efficiency matters.
- DTF printing offers impressive turnaround speeds, combining quick prep with minimal setup.
- Plastisol Transfers are another smart option, letting you print and store designs in advance and heat press them onto shirts as needed.
- HTV is also efficient for personalisation tasks, especially when customising names or numbers on jerseys or leavers' tops.
By matching your needs to the right printing method, you can get better results, save money, and ensure your shirts look sharp from the first wear to the last. Whether it’s for school teams, club uniforms, or promotional apparel, the right choice starts with understanding what works best for your job
Choose the Right Shirt Printing Method for Long-Lasting, Custom Results
From bold screen prints to breathable sublimation and premium embroidery, understanding the different types of shirt printing can help you make smarter choices for your uniforms, merchandise, or event apparel. Whether you're ordering for a school, sports team, or community group, the right print method can enhance durability, comfort, and style, all while staying on budget.
Still unsure which option is best for your needs? At Team Spirit Sports, we specialise in high-quality, custom sportswear and uniforms tailored for Australian schools and clubs. Our team can help you select the ideal printing method based on your fabric, design, and order size.
Get in touch today to discuss your next custom order and create gear that performs as well as it looks.