Screen Printing Requires Screens — DTF Doesn’t

One of the biggest differences between traditional apparel printing and modern methods comes down to one simple fact: screen printing requires screens — DTF doesn’t. This single difference affects cost, turnaround time, design flexibility, and how easily you can scale your apparel business.

If you’ve ever dealt with screen setup fees, color limitations, or slow reorders, understanding why DTF (Direct-to-Film) printing skips screens entirely will help you choose the smarter printing method for today’s market.

Why Screen Printing Requires Screens

Screen printing is a stencil-based process. Every design must be separated into colors, and each color requires its own physical screen.

What That Means in Practice

For a single screen-printed design:

  • Each color = one screen

  • Screens must be coated, exposed, washed, dried, and aligned

  • Setup happens before printing even begins

A simple 4-color logo requires:

  • 4 separate screens

  • 4 setup processes

  • Careful registration to align colors

This is why screen printing is time-consuming and expensive to set up—especially for small or custom orders.

The Hidden Costs of Screens

Because screens are required, screen printing typically involves:

  • Setup fees per color

  • Higher costs for detailed or multi-color artwork

  • Longer turnaround times

  • Inefficient reorders (screens may need to be recreated)

  • Minimum order requirements to justify setup labor

Screen printing can still make sense for very large bulk runs with simple artwork—but it struggles with flexibility.

Why DTF Doesn’t Need Screens

DTF (Direct-to-Film) printing works completely differently.

Instead of burning screens, DTF:

  • Prints your artwork digitally onto film

  • Applies adhesive powder

  • Cures the design

  • Produces a heat press-ready transfer

There are:

  • ❌ No screens

  • ❌ No color separations

  • ❌ No setup per design

  • ❌ No added cost for complex artwork

Your design prints exactly as submitted—every time.

What “No Screens” Really Means for Your Business

Skipping screens changes everything.

✅ Unlimited Colors

DTF prints full-color designs in a single pass. Whether your artwork has 2 colors or 200, the process stays the same.

✅ No Setup Fees

Because there’s no screen creation, there are no per-color or per-design setup charges.

✅ Faster Turnaround

Orders move straight into production without waiting on screen prep.

✅ Easy Reorders

Reordering is as simple as submitting the same file again—no screens to recreate.

✅ No Minimums

Since setup isn’t required, DTF works just as well for one transfer as it does for bulk orders.

Screen Printing vs DTF: Setup Comparison

Feature Screen Printing DTF Printing
Requires Screens Yes No
Setup Time High None
Setup Fees Per color None
Color Limits Practical limits Unlimited
Small Orders Costly Cost-effective
Reorders Slower Fast
Design Complexity Limited No limits

Why Many Businesses Are Moving Away from Screens

For modern apparel production, screens often slow things down. DTF offers flexibility that screen printing can’t match, especially for:

  • Streetwear brands with frequent design changes

  • Small businesses fulfilling custom orders

  • Schools and teams ordering mixed designs

  • Event merch with tight deadlines

  • Shops handling both small and bulk jobs

DTF removes the bottlenecks that screens create.

How DTFRVA Makes Screen-Free Printing Easy

DTFRVA specializes in screen-free DTF transfers, giving you the freedom to print without limitations.

Two Easy Ordering Options

Upload a print-ready gang sheet:
https://dtfrva.com/products/upload-your-pre-made-gang-sheet

Build a gang sheet online (no design software needed):
https://dtfrva.com/products/build-your-own-gang-sheet

Both options allow unlimited colors, fast production, and zero setup.

When Screen Printing Still Makes Sense

Screen printing isn’t obsolete—it just has a narrower use case.

Screen printing can still work well when:

  • Designs use 1–2 solid colors

  • Orders are very large (hundreds or thousands of pieces)

  • Setup cost is spread across bulk volume

But for most modern workflows, screens add friction instead of value.

Final Takeaway

Screen printing requires screens — DTF doesn’t.
That difference eliminates setup fees, color limitations, and production delays.

If you want:

  • Unlimited colors

  • Faster turnaround

  • No setup costs

  • Easy reorders

  • Flexible order sizes

DTF is the smarter, more scalable printing solution.

Back to blog