Screen Printing vs DTG vs Heat Transfer: Best Method for Ampersand Shirts

Published: January 2025 | 12 min read

You've created the perfect ampersand design. Now comes the critical decision: how should you print it? The printing method you choose dramatically affects cost, quality, durability, and how your shirts look and feel.

This comprehensive guide breaks down the three main printing methods—screen printing, direct-to-garment (DTG), and heat transfer—with specific recommendations for ampersand designs. We'll cover costs, quality, durability, minimum orders, and exactly when to use each method.

Quick Comparison Overview

Factor Screen Printing DTG Heat Transfer
Best for ampersand? Excellent ✓✓✓ Good ✓✓ Good ✓✓
Minimum order 12-24 shirts 1 shirt 1 shirt
Cost (small qty) $$$ (high setup) $$ (moderate) $ (lowest)
Cost (large qty) $ (lowest) $$ (moderate) $$$ (highest)
Durability Excellent (100+ washes) Very Good (50+ washes) Good (30-50 washes)
Feel/Hand Slight texture Soft, no texture Noticeable texture
Color options Limited (cost per color) Full color Full color
Production time 7-14 days 3-7 days 1-3 days

Method 1: Screen Printing

How Screen Printing Works

Ink is pushed through a mesh screen (one screen per color) directly onto the fabric. Each screen is custom-made for your design, which is why there's a setup cost. The ink sits on top of the fabric and bonds when heat-cured.

✓ Pros for Ampersand Designs

  • Incredibly durable—lasts 100+ washes
  • Vibrant, bold colors (perfect for ampersand text)
  • Most cost-effective for bulk orders (20+ shirts)
  • Crisp, clean lines on text
  • Works on any shirt color
  • Professional, commercial-grade quality

✗ Cons

  • High setup costs ($25-75 per color)
  • Minimum order quantities (usually 12-24)
  • Each color adds cost
  • Longer production time (7-14 days)
  • Slight texture/hand feel
  • Design changes require new screens

Cost Breakdown: Screen Printing

Setup Costs:

Per-Shirt Costs (one-color print):

Total Cost Example (50 shirts, one color):

Why Screen Printing is Perfect for Ampersand Designs

Best For Ampersand Designs:

✓ Orders of 20+ shirts
✓ Single-color designs
✓ Sports teams, family reunions, corporate events
✓ When you need maximum durability
✓ Budget-conscious bulk orders

Create Your Screen-Print Ready Design

Export high-resolution files perfect for screen printing

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Method 2: Direct-to-Garment (DTG)

How DTG Works

Think of it as an inkjet printer for shirts. The printer sprays water-based ink directly into the fabric fibers. The ink is absorbed and bonds with the fabric, creating a soft finish with no texture.

✓ Pros for Ampersand Designs

  • No minimum order—order just 1 shirt
  • No setup fees
  • Soft feel—no texture on the fabric
  • Full color capability (though ampersand usually uses one)
  • Great detail for small text
  • Fast turnaround (3-7 days)
  • Easy to make design changes

✗ Cons

  • More expensive per shirt than screen printing (at volume)
  • Best on light-colored shirts (white/cream/light gray)
  • Dark shirts require underbase = thicker feel
  • Less durable (50-75 washes vs 100+ for screen)
  • Colors can fade faster
  • Not all fabrics work (100% cotton best)

Cost Breakdown: DTG

Per-Shirt Costs:

Light vs Dark Shirts:

Total Cost Example (10 shirts, one color on white):

DTG for Ampersand Designs: Considerations

Best For Ampersand Designs:

✓ Small orders (1-15 shirts)
✓ Light-colored shirts
✓ Testing designs before bulk orders
✓ Print-on-demand businesses
✓ Quick turnaround needs
✓ Soft-feel preference

Method 3: Heat Transfer (Vinyl & Sublimation)

Heat transfer actually includes several sub-methods:

A. Heat Transfer Vinyl (HTV)

How HTV Works

Your design is cut from a sheet of colored vinyl using a cutting machine (like Cricut or Silhouette), then heat-pressed onto the shirt. The vinyl sits on top of the fabric and bonds through heat and pressure.

✓ Pros for Ampersand Designs

  • DIY-friendly—you can do this at home
  • No minimum orders
  • Immediate production (make it today)
  • Clean, crisp lines
  • Works on any fabric color
  • Many vinyl color options

✗ Cons

  • Noticeable texture/thickness on shirt
  • Can peel or crack over time
  • Limited to solid colors (no gradients)
  • Time-consuming for large quantities
  • Small details can be hard to weed
  • Not dishwasher safe (inside-out wash only)

Cost Breakdown: HTV (DIY)

Initial Investment:

Per-Shirt Costs (after equipment):

Break-Even Point: 30-50 shirts vs. outsourced printing

B. Sublimation Transfer

How Sublimation Works

Design is printed on special paper with sublimation ink, then heat-pressed onto polyester fabric. The heat turns the ink into gas, which bonds with the polyester fibers. Becomes part of the fabric.

✓ Pros

  • No texture at all—softest feel
  • Won't crack, peel, or fade
  • Full color capability
  • Extremely durable

✗ Cons

  • ONLY works on white or light polyester
  • Requires polyester fabric (many prefer cotton)
  • Requires special printer and inks
  • Not ideal for ampersand text (better for photos)

Heat Transfer Best For Ampersand Designs:

✓ DIY/craft enthusiasts
✓ Very small batches (1-10 shirts)
✓ Immediate need (can't wait for production)
✓ Testing before larger order
✓ One-off custom names/personalization

Head-to-Head: Which Method Wins?

Scenario 1: Youth Soccer Team (30 shirts)

Design: "Forward & Midfield & Defense & Goal" in white on navy shirts

Winner: Screen Printing

Scenario 2: Bachelorette Party (8 matching shirts)

Design: "Bride & Squad & Nash & Bash" in rose gold on white shirts

Winner: DTG

Scenario 3: Testing Design Before Big Order (2-3 samples)

Design: Any ampersand design

Winner: DTG or HTV (DIY)

Scenario 4: Family Reunion (75 shirts, all sizes)

Design: "Smith & Family & Reunion & 2024" in black on white shirts

Winner: Screen Printing

Scenario 5: Personalized Grandparent Shirts (1 shirt each, different names)

Design: "Grandma & [grandkid names] & Love" (each shirt has different names)

Winner: DTG

Export for Any Printing Method

Our generator creates files that work with screen printing, DTG, and heat transfer

Create Design →

File Preparation: What Printers Need

For Screen Printing

For DTG

For Heat Transfer Vinyl

Quality Control: How to Evaluate Your Prints

Inspect Before Accepting Order

Check for:

Wash Test (Before Bulk Distribution)

  1. Wash one sample shirt inside-out in cold water
  2. Tumble dry low or hang dry
  3. Check for cracking, fading, or peeling
  4. Evaluate softness/hand feel after wash

Pricing Decision Tree

If ordering 1-10 shirts:

If ordering 11-19 shirts:

If ordering 20-50 shirts:

If ordering 50+ shirts:

If each shirt is personalized differently:

If you need them TODAY:

Common Mistakes to Avoid

1. Choosing Method Based on Price Alone

Mistake: Picking cheapest option without considering durability

Fix: Factor in cost-per-wear and replacement costs

2. Not Ordering Samples First

Mistake: Ordering 100 shirts without seeing a printed sample

Fix: Always order 1-2 samples before bulk production

3. Wrong File Format for Printing Method

Mistake: Sending low-res JPG to screen printer

Fix: Ask printer for file specs before submitting design

4. Ignoring Fabric Compatibility

Mistake: Ordering DTG on 50/50 poly-blend (poor results)

Fix: Match printing method to fabric type

5. Not Reading Wash Instructions

Mistake: Hot wash + dryer = destroyed prints

Fix: Always wash inside-out, cold water, low heat dry

The Verdict for Ampersand Designs

Best Overall: Screen Printing

Ampersand designs are PERFECT for screen printing because:

  • Usually single-color (low cost)
  • Bold text benefits from screen printing crispness
  • Most orders are 20+ shirts (bulk pricing)
  • Maximum durability for frequently-worn shirts
  • Professional quality matches modern aesthetic

Use DTG when: Small quantity (under 20 shirts), personalized designs, or fast turnaround needed

Use Heat Transfer when: DIY enthusiast, immediate need, or testing before bulk order

Conclusion: Match Method to Your Needs

There's no universally "best" printing method—only the best method for your specific situation. Screen printing dominates for team orders and bulk quantities. DTG shines for small batches and personalization. Heat transfer works for DIY and immediate needs.

For most ampersand shirt orders (sports teams, family reunions, events), screen printing delivers the best combination of quality, durability, and value. But don't be afraid to use DTG for small orders or testing—it's come a long way and produces excellent results.

The key is understanding your priorities: quantity, budget, timeline, and quality expectations. Make your decision based on data, not assumptions.

Ready to create your printable design? Start designing now →