Printing Methods
Which printing method is right for your product? Screen printing, flexographic printing, digital printing, pad printing, and UV printing differ significantly in terms of appearance, durability, applications, and cost. The question of whether a white underprint is needed can also be decisive for the final print result. In our overview, we’ll show you the key differences and help you find the right process for your design and product.
Hinweis: Die Empfehlung ist eine erste Orientierung. Material, Druckgröße, exakte Farben und Aufbereitung der Druckdaten können die Auswahl und den Preis beeinflussen.
Textile Printing Methods
| Eignung / Eigenschaft | Siebdruck | Flexdruck | Digitaldruck |
|---|---|---|---|
| 1. Stückzahlen | |||
| Einzelstücke / kleine Auflagen | ● | ✓ | ✓ |
| Mittlere Auflagen | ● | ✓ | ✓ |
| Große Auflagen | ✓ | ● | ● |
| 2. Kosten & Wirtschaftlichkeit | |||
| Geringe Einrichtungskosten | ✕ | ✓ | ✓ |
| Kosten bei kleinen Stückzahlen | eher hoch | günstig | günstig |
| Kosten bei großen Stückzahlen | sehr günstig | eher höher | mittel |
| Kosten steigen mit Anzahl der Druckfarben | ✓ | ● | ✕ |
| 3. Motive, Farben & Details | |||
| Einfache Logos, Schrift & Farbflächen | ✓ | ✓ | ✓ |
| Mehrfarbige Motive | ✓ | ● | ✓ |
| Sehr feine Details | ✓ | ● | ✓ |
| Farbverläufe | ● | ✕ | ✓ |
| Fotomotive | ● | ✕ | ✓ |
| Namen & Nummern | ● | ✓ | ✓ |
| 4. Haltbarkeit & Tragegefühl | |||
| Waschbeständigkeit | ✓ | ✓ | ● |
| Haltbarkeit bei häufiger Nutzung | ✓ | ✓ | ● |
| Spürbarkeit des Drucks | ● | ● | ● |
Screen Printing
In screen printing, the ink is printed directly onto the product through a fine-mesh screen. A separate screen is generally required for each ink color. This process produces vibrant, opaque colors and is known for its high durability.
Suitable for: textiles, bags, workwear, and a wide variety of durable promotional items.
Advantages: Excellent color coverage, vibrant colors, long-lasting results, and particularly cost-effective for larger quantities.
Costs: Setting up and producing the screens results in relatively high setup costs. However, the larger the print run, the lower the cost per print typically becomes. For multicolor designs, costs increase because additional steps are required for each color.
Underprint: On dark textiles or dark materials, a white underprint is often applied so that the actual design colors appear vibrant and true to color. The underprint is usually counted as an additional color or print pass.
Please note: For small print runs and designs with many colors, screen printing is often less cost-effective. Color gradients and photorealistic designs are generally possible using halftone printing, but the process is more labor-intensive than with digital methods.
Flex printing
In flex printing, the design is cut out of a special, single-color transfer film. The unused areas of the film are removed, and the design is then transferred to the fabric using heat and pressure.
Suitable for: T-shirts, jerseys, team uniforms, and workwear—especially for names, numbers, lettering, and simple logos.
Advantages: Very high opacity, intense colors, clean contours, and cost-effective even for single items or small quantities.
Costs: Usually inexpensive for small quantities, since no printing screens or plates need to be produced. For larger print runs, however, the time and effort required for cutting, weeding, and transfer may be greater than with other methods.
Base color: A separate base color is not usually required. The film used is opaque on its own and can therefore also be applied to dark fabrics.
Please note: Traditional flex printing is best suited for single-color and simple designs. Photos, subtle color gradients, and very complex designs cannot be produced using this method, or can only be produced using other transfer methods.
Digital Printing
In digital printing, the design is processed directly from digital data without the need to create a separate printing plate for each color. Depending on the product, different digital printing methods are used, such as direct-to-fabric printing or digital transfer methods.
Suitable for: photos, illustrations, color gradients, multicolored logos, and complex designs.
Advantages: Virtually unlimited color options, high level of detail, and photorealistic images. Particularly well-suited for one-of-a-kind items as well as small and medium-sized print runs.
Costs: Since no separate printing screens or plates are required, setup costs are generally low. This makes digital printing particularly cost-effective for smaller print runs and designs with many colors. For very large print runs, conventional methods such as screen printing may be more cost-effective.
Underprint Color: In many digital printing processes, white is used as an underprint color on dark materials or textiles. This prevents the product’s base color from showing through the design. For light-colored or white products, this step is often not necessary.
Please note: The texture, color appearance, and durability vary depending on the digital printing process, material, and pretreatment used.
Pad Printing
In pad printing, the design is first applied to a printing plate. An elastic silicone pad picks up the ink and then transfers it to the product. Thanks to its flexibility, the pad can adapt to curved or irregular surfaces.
Suitable for: ballpoint pens, key chains, lighters, technical components, and numerous small promotional items.
Advantages: Ideal for small, curved, or hard-to-reach printing surfaces. Fine logos, lettering, and details can be reproduced with great precision.
Costs: The production of the printing plate and setup incur basic costs. Therefore, pad printing becomes more cost-effective as the quantity increases. The number of printing inks also affects the price, since they are typically printed individually.
Background Color: On dark or transparent materials, a white background may be necessary to ensure that the design colors provide sufficient coverage. This is typically treated as an additional print pass and may incur additional costs accordingly.
Please note: There are technical limitations on the print area and the number of colors. For large areas, photos, or complex color gradients, there are usually more suitable methods.
UV Printing
In UV printing, special inks are applied directly to the surface of the product and immediately cured with UV light. As a result, the ink does not dry in the traditional way, but cures within a very short time.
Suitable for: plastic, metal, glass, wood, acrylic, and many other solid materials, as well as flat promotional items.
Advantages: High level of detail, vibrant colors, color gradients, and photorealistic designs. Even small batch sizes and customized products can be produced cost-effectively.
Costs: Since no traditional printing plates need to be produced, setup costs are relatively low. This makes UV printing particularly well-suited for small- and medium-volume runs as well as personalized products. For very large quantities, screen printing or pad printing may be more cost-effective.
Underprint Color: In UV printing, white can be specifically used as a separate ink. On dark, transparent, or colored materials, white is often printed underneath the design first. This ensures that the actual colors of the design remain vibrant and true to color. For transparent products, white can also be used as a design element or a barrier layer.
Please note: Traditional direct UV printing is primarily suitable for rigid materials. Depending on the machine and printing technique, flexible or highly curved products can only be printed to a limited extent.
Sublimation Printing
In sublimation printing, the ink is permanently fused into the material under heat and pressure. This process is particularly well-suited for light-colored textiles with a high polyester content, as well as for specially coated promotional items, such as mugs or aluminum plates.
Advantages: Brilliant colors, fine details, color gradients, and photographic images can be reproduced very well. The print is not noticeable to the touch, as the ink becomes part of the material, and it is highly durable.
Costs: Since no printing screens or comparable setup costs are required, sublimation printing is also a viable option for small quantities. Cost-effectiveness depends primarily on the product, the print area, and the print run.
Background color: A white background color is not possible and is not used. For this reason, sublimation printing generally works only on white or very light-colored materials. On dark textiles, the colors are not sufficiently visible.
Please note: Sublimation printing is generally not suitable for cotton and dark fabrics. For fabrics, the polyester content should be as high as possible to ensure optimal color and durability.