- Screen printing pushes ink through one mesh screen per color, so designs with 1 to 6 colors on cotton suit it best.
- Dark garments need a white underbase, which counts as an extra color and an extra screen.
- Pantone-matched spot colors are usually the right choice, while CMYK process and halftones show dots up close.
- Standard turnaround is 7 to 14 business days, so order 2 to 3 weeks ahead.
What is Screen Printing?
Screen printing, also called silk screening, is the method that built the custom apparel industry. Ink forced through mesh screens, directly onto fabric. No middleman, no shortcuts. Just a process that's been proven for decades and remains the undisputed gold standard for bulk orders.
Best for:
- Bulk orders (50+ pieces)
- Simple designs (1-6 colors)
- Cotton garments
- Lowest cost per unit at scale
- Maximum durability (50+ washes)
Screen Creation Process
Every screen print job starts long before ink touches fabric. Here's exactly how it works:
- Artwork Separation: The design is broken into individual color layers: one layer per color
- Film Output: Each color is printed onto clear film as a positive
- Screen Coating: A mesh screen is coated with light-sensitive photo emulsion
- Exposure: The film and screen are exposed together under UV light
- Washout: Unhardened emulsion washes away, leaving a precise ink stencil
- Setup: Screens are mounted and registered on press (MNR Cobra 8/10, 10 platens)
Screen Life: Screens are $32 per color, per print location, and are re-made for each run.
Setup Fees Explained
Screen printing has upfront costs. Understand them, and they stop being a surprise.
New Screens: $32/screen Reprint (Existing Screens): $20/screen Underbase (Dark Garments): +1 to your color count
Example: 3-color design on a dark garment
- Colors: 3 + underbase = 4 screens
- New setup: 4 × $32 = $128
- Reprint later: 4 × $20 = $80 (save $48 every time)
Setup is a one-time cost per design. The larger your order, the less it matters, it amortizes fast.
Color Separation Guide
How your artwork gets separated determines everything about print quality. Choose the wrong method and you'll notice it on press.
Spot Colors (Pantone Matching):
- Exact brand color matching, no guessing
- Solid, vibrant output
- Best for logos, text, and clean graphics
- No practical limit on number of colors
CMYK Process (4-Color):
- Technically possible, but rarely the right call
- Halftone dot pattern is visible up close
- Colors are less vibrant than spot
- Reserve this for photorealistic needs only
Halftones for Gradients:
- Dot patterns create the illusion of gradients
- Visible on close inspection, that's the tradeoff
- Requires skilled separations to execute well
- Not the right choice if you need smooth, seamless transitions
Bottom line: Spot colors win for most screen printing jobs. If your design lives in the real world, on chests, backs, and sleeves, Pantone-matched spot colors are what make it look sharp.
Bulk Pricing Tiers (Tier 2 - Business)
| Quantity | 1 Color | 2 Colors | 3 Colors | 4 Colors | 5 Colors | 6 Colors |
|---|---|---|---|---|---|---|
| 1-49 pcs | $18.00 | $20.00 | $22.00 | $24.00 | $26.00 | $28.00 |
| 50-99 pcs | $15.00 | $17.00 | $19.00 | $21.00 | $23.00 | $25.00 |
| 100-249 pcs | $12.00 | $14.00 | $16.00 | $18.00 | $20.00 | $22.00 |
| 250-499 pcs | $9.50 | $11.50 | $13.50 | $15.50 | $17.50 | $19.50 |
| 500+ pcs | $8.00 | $10.00 | $12.00 | $14.00 | $16.00 | $18.00 |
Setup fees are additional, see the section above.
The math gets better fast as quantity climbs. That's the entire point of screen printing.
Real Cost Breakdown
Numbers on a pricing table only tell part of the story. Here's what all-in actually looks like.
Example 1: Corporate Event (150 polos)
- Garment: Gildan 5000 @ $8.00/polo
- Print: 2-color logo, left chest
- Print cost: $14.00 × 150 = $2,100
- Setup: 2 × $32 = $64
- Garments: $8.00 × 150 = $1,200
- Total: $3,364, $22.43/piece all-in
Example 2: Retail Brand (500 tees)
- Garment: Gildan 3000 @ $4.19/tee
- Print: 1-color text, front
- Print cost: $8.00 × 500 = $4,000
- Setup: 1 × $32 = $32
- Garments: $4.19 × 500 = $2,095
- Total: $6,127, $12.25/piece all-in
At 500 pieces, that setup fee is essentially invisible. That's scale working in your favor.
Screen Print vs DTF
Two methods. Different strengths. Knowing which one fits your order saves you money every time.
| Factor | Screen Print | DTF |
|---|---|---|
| Setup Fees | $32/screen | $0 |
| Best Quantity | 50+ pieces | 1-50 pieces |
| Color Limits | 1-6 colors | Unlimited (CMYK) |
| Turnaround | 7-14 days | 1-2 days |
| Durability | 50+ washes | 30-40 washes |
| Cost at 24 pcs | $18-24 + setup | $11/piece |
| Cost at 100 pcs | $12-16 + setup amortized | $9.20/piece |
| Cost at 500 pcs | $8-10 + minimal setup/piece | $8-10/piece (no savings) |
Break-even: Approximately 60 pieces for a 2-color design.
Under 60 pieces? DTF is probably your answer. Over 60? Screen printing wins on cost and durability, and the gap widens the larger you go.
Underbase for Dark Garments
Print on a dark garment without an underbase and the results are predictable: muddy colors, bleed-through, a finished product that doesn't represent your brand.
What is underbase? A white base layer printed first. Your colors go on top of it, not the fabric.
Why it matters:
- Blocks the garment color from bleeding through
- Keeps your colors vibrant and true to spec
- Required for black, navy, charcoal, and any dark substrate
The cost impact:
- Underbase counts as an additional color
- A 2-color design on a dark garment = 3 screens (2 colors + underbase)
- Setup: 3 × $32 = $96 vs. 2 × $32 = $64 on a light garment
It's worth every penny. Skipping the underbase to save $32 in setup is how you end up reprinting the whole order.
Ink Types & Colors
The ink you choose affects feel, durability, and vibrancy. Here's what we work with.
Plastisol Ink (Standard):
- PVC-based, exceptionally durable
- Vibrant, consistent color output
- Heat cured at 320°F for 60 seconds
- Industry standard for a reason
Water-Based Ink:
- Eco-friendly with a softer hand feel
- Less vibrant on dark garments
- Air dry or heat cure options
- Growing in popularity for premium retail applications
Specialty Inks:
- Metallic, glitter, glow-in-the-dark
- High-density (raised, puffy texture)
- Discharge (bleeds into the fiber for a vintage look)
- Additional cost applies, ask for details
Turnaround Times
Standard: 7-14 business days Rush: depends on our schedule, call to confirm your date
What's actually happening during that time:
- Art approval: 24-48 hours
- Screen creation: 2-4 hours per screen
- Press setup: 30-60 minutes
- Printing: 100-200 pieces/hour
- Curing: 60 seconds per garment
- QC + packing: 2-4 hours
Plan for 2-3 weeks from art approval to delivery. Cutting it close never ends well.
Artwork Requirements
Send us the right files and everything moves fast. Send us the wrong ones and we're adding days to your timeline.
Accepted File Formats:
- AI, EPS, PDF (vector preferred, always)
- PNG (300+ DPI minimum, transparent background)
- Each color on a separate layer
Color Mode:
- Spot colors (Pantone), the right call for screen printing
- CMYK converts to spot and may shift; confirm before submitting
- RGB is not acceptable, convert before sending
Resolution:
- Vector files: unlimited scalability
- Raster files: 300 DPI minimum at print size
Separation Notes:
- Specify Pantone colors wherever possible
- Indicate whether you need an underbase
- Always tell us the garment color, it changes everything
Durability Testing
Screen printing doesn't just look good on day one. It holds up.
Wash Cycle Testing:
- 50+ washes with no fading, cracking, or peeling
- Recommended care: cold water, gentle cycle, inside out
- Built for work uniforms, athletic jerseys, and anything that sees daily use
Fade Resistance:
- 200 hours of UV exposure: less than 5% degradation
- Significantly outperforms DTF for outdoor and high-wear applications
- The right choice for retail resale inventory that needs to look good after months on the shelf
Best Use Cases
Choose screen printing when:
- You're ordering 50+ pieces
- Your design uses 1-6 colors
- Durability is non-negotiable: work uniforms, athletic wear
- You're scaling to 100+ pieces and want the best cost-per-unit
- You need consistent, professional results for corporate branding
- You're building retail inventory that has to last
Skip screen printing when:
- You need fewer than 50 pieces, DTF is cheaper
- Your design includes photos, gradients, or complex illustrations
- You need it in less than a week
- You're running a sample or proof before a larger order
- Setup costs aren't in the budget yet
Common Mistakes
These are the errors we see most often. All of them are preventable.
Mistake #1: Ordering Too Late Standard turnaround is 7-14 business days, not calendar days. Order 2-3 weeks ahead, every time.
Mistake #2: Ignoring Setup Fees At $32/screen, a 4-color job on dark garments starts at $128 before a single shirt is printed. Run the full math before you commit.
Mistake #3: Overcomplicating the Design Every color is another screen, another $32, and another variable. Simplify your design. Fewer colors almost always look cleaner anyway.
Mistake #4: Forgetting the Underbase Dark garment orders without underbase discussions cause reprints. Tell us the garment color upfront, every time.
Mistake #5: Submitting Low-Resolution Art Screen printing requires vector files. If your designer can't provide AI, EPS, or PDF, that's the first conversation to have before you contact us.
Get a Quote
You've done the research. Now let's make it happen.
Getting a quote from Arnold Prints takes minutes, and there's no obligation. Whether you're pricing out 50 polos for a corporate event or 500 tees for a retail launch, we'll give you exact numbers fast.
Three ways to get started:
Business Quote Form: Best for detailed orders; we respond same business day
DTF Calculator: Run a side-by-side comparison of screen print vs. DTF before you decide
Email: sales@arnoldprints.com
Call: (561) 323-7573
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