How do I choose a print method for merch?

For printing a one- or two-color logo in large quantities, screen printing is the right method, and apparel uses garment screen printing on the same principle. The screen cost is paid once at the start, so the unit price falls as quantity rises.

Designs with photos or gradients are printed with digital methods that reproduce full color without plates. Rigid products usually use UV printing or UV film, and apparel usually uses DTF or sublimation.

For a logo that cannot wear off on tumblers or metal products, laser engraving is the right method. Laser engraving marks the material itself, so there is no ink to peel, and on a coated tumbler the metal base under the coating shows through in the shape of the logo.

Laser engraving uses no ink, so the logo color is limited to the single color of the material.

For a long-lasting logo on caps or uniforms, embroidery is the right method. Embroidery is stitched with thread, so the logo has a raised look and holds up to washing.

Small text and thin lines are hard to stitch, so prepare the logo in a bold, simple form.

When printing on dark garments or clear products, first check whether a white base print is needed so colors do not sink into the background. Sublimation lets the base color show through, so sublimation does not suit dark fabric.

For small quantities or many design versions, plateless digital methods such as UV printing, UV film and DTF keep setup costs low.

For an exact match to a brand color (Pantone), screen printing with mixed ink or offset printing with spot-color plates works better. Digital methods approximate colors with CMYK, so some color difference can occur.

For cups or tumblers that go in the dishwasher, consider laser engraving before surface-applied UV film. UV film can lose adhesion after repeated hot washing, while laser engraving marks the material and does not wash off.