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:
- Single color: $25-50 setup fee
- Two colors: $50-75 total setup
- Three+ colors: $75-150+ setup
Per-Shirt Costs (one-color print):
- 12-24 shirts: $10-15 each
- 25-50 shirts: $8-12 each
- 50-100 shirts: $6-10 each
- 100+ shirts: $5-8 each
Total Cost Example (50 shirts, one color):
- Setup: $35
- Printing: $9 × 50 = $450
- Total: $485 ($9.70 per shirt)
Why Screen Printing is Perfect for Ampersand Designs
- Single-color designs: Most ampersand shirts use one color = low setup cost
- Bold text: Screen printing makes text incredibly crisp and readable
- Team orders: Sports teams, families, events typically order 20+ shirts = perfect volume
- Durability needs: These shirts get worn repeatedly—screen printing holds up
- Professional quality: The commercial look matches the professional aesthetic of 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
Design Now →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:
- 1-5 shirts: $18-25 each
- 6-12 shirts: $15-20 each
- 13-24 shirts: $12-18 each
- 25+ shirts: $10-15 each
Light vs Dark Shirts:
- Light shirts: standard pricing
- Dark shirts: add $3-5 per shirt (requires white underbase)
Total Cost Example (10 shirts, one color on white):
- No setup fee
- Printing: $17 × 10 = $170
- Total: $170 ($17 per shirt)
DTG for Ampersand Designs: Considerations
- Small orders: Perfect for testing designs or small friend groups
- Light shirts: Best results on white, cream, or light gray shirts
- Soft feel: Great if you hate the texture of screen printing
- Quick turnaround: Need shirts fast? DTG delivers
- Print-on-demand: Most POD services use DTG
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:
- Cricut or Silhouette machine: $200-400
- Heat press: $150-300 (or home iron for cheaper option)
- Vinyl rolls: $10-15 per 12" × 10' roll
- Transfer tape: $8-12 per roll
- Weeding tools: $10-20
- Total startup: $380-750
Per-Shirt Costs (after equipment):
- Blank shirt: $5-12
- Vinyl: $0.50-2 (depending on design size)
- Transfer tape: $0.25
- Total: $6-15 per shirt
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
- Cost: ~$300-350 ($10-12 per shirt)
- Maximum durability for active kids
- Professional quality
- Best value at this quantity
Scenario 2: Bachelorette Party (8 matching shirts)
Design: "Bride & Squad & Nash & Bash" in rose gold on white shirts
Winner: DTG
- Cost: ~$140-160 ($17-20 per shirt)
- No minimums, no setup fee
- Fast turnaround
- Soft feel for all-day wear
Scenario 3: Testing Design Before Big Order (2-3 samples)
Design: Any ampersand design
Winner: DTG or HTV (DIY)
- DTG: $20-25 each, quick online order
- HTV: $10-15 each if you have equipment
- See the design in person before committing to 50+ shirts
Scenario 4: Family Reunion (75 shirts, all sizes)
Design: "Smith & Family & Reunion & 2024" in black on white shirts
Winner: Screen Printing
- Cost: ~$500-600 ($6.50-8 per shirt)
- Best economics at this volume
- Durability means keepsake quality
- Can reorder matching shirts later with same screens
Scenario 5: Personalized Grandparent Shirts (1 shirt each, different names)
Design: "Grandma & [grandkid names] & Love" (each shirt has different names)
Winner: DTG
- Cost: $20-25 each
- Easy personalization
- No minimums
- Each design is unique
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
- Format: Vector (AI, EPS, PDF) preferred, or high-res PNG (300 DPI)
- Colors: Specify Pantone colors or provide color codes
- Background: Transparent
- Size: Actual print size (typically 12-14" wide for adult shirts)
For DTG
- Format: PNG with transparent background, 300 DPI minimum
- Size: At least 12" × 15" at 300 DPI (3600 × 4500 pixels)
- Color mode: RGB for light shirts, CMYK for dark shirts
- File size: Usually no larger than 25MB
For Heat Transfer Vinyl
- Format: SVG (vector) strongly preferred
- Details: No elements smaller than 0.25"
- Font: Convert text to paths/outlines
- Colors: Solid colors only (choose vinyl color)
Quality Control: How to Evaluate Your Prints
Inspect Before Accepting Order
Check for:
- Registration accuracy (text aligned properly)
- Clean edges (no bleeding or fuzzy lines)
- Consistent color across all shirts
- Proper ink coverage (no thin/streaky areas)
- Correct placement (centered, proper distance from collar)
Wash Test (Before Bulk Distribution)
- Wash one sample shirt inside-out in cold water
- Tumble dry low or hang dry
- Check for cracking, fading, or peeling
- Evaluate softness/hand feel after wash
Pricing Decision Tree
If ordering 1-10 shirts:
- → DTG (best value, no minimums)
If ordering 11-19 shirts:
- → DTG or Screen Printing (get quotes for both)
If ordering 20-50 shirts:
- → Screen Printing (better value, professional quality)
If ordering 50+ shirts:
- → Screen Printing (significantly cheaper per shirt)
If each shirt is personalized differently:
- → DTG (screen printing can't do this economically)
If you need them TODAY:
- → Heat Transfer Vinyl DIY (if you have equipment)
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 →