Iron-On Transfers vs Screen Printing: Cost Comparison
The cost comparison between iron-on transfers and screen printing depends entirely on quantity. Screen printing has a high setup cost (£50-150 per colour per screen) that is amortised over the print run. Iron-on transfers have no setup cost but a higher per-unit price. The crossover point where screen printing becomes cheaper is typically around 50-100 units for a single-colour design.
Cost at Different Quantities
At 1-10 units, iron-on transfers are dramatically cheaper. A DTF transfer costs £1.99-7.99 depending on size. A screen printer would charge £50-150 for screen setup alone, making the per-unit cost £15-30+ before you add the garment cost.
At 25-50 units, iron-on transfers are still cheaper for multi-colour designs. Screen printing setup for a 4-colour design can run £200-400. DTF transfers print full colour at no extra cost.
At 100+ units, screen printing starts to win on per-unit cost for simple designs. Once the screens are set up, each additional print costs very little (£1-3 per unit). DTF per-unit cost stays relatively flat.
At 500+ units, screen printing is clearly cheaper per unit. But you need to order all 500 upfront. DTF lets you order as-needed with no dead stock.
Hidden Costs of Screen Printing
Screen printing quotes often exclude several costs that affect the true per-unit price. Setup fees (£50-150 per colour) are charged every time you re-order, even for repeat designs. Minimum order quantities (typically 25-50) mean you pay for shirts you may not need. Artwork fees apply if the printer needs to prepare your design. Delivery charges for heavy boxes of printed shirts add £10-30.
DTF transfers have none of these hidden costs. The price you see is the price you pay. No setup fees, no minimum order, no artwork charges, and standard delivery is included.
Quality Differences
Screen printing and DTF produce different finishes. Screen printing deposits thick ink directly onto the fabric, creating a flat, matte finish that is slightly raised. DTF transfers produce a thinner, more flexible print with a subtle sheen.
For single-colour logos on cotton t-shirts, screen printing is the traditional gold standard. For full-colour photos, gradients, and complex artwork, DTF produces better results because it is not limited by the number of screens.
Both methods are durable - screen prints and DTF transfers both last 50+ washes with proper care.
When Each Method Wins
Choose DTF transfers when: you need 1-50 units, every item can be different, you need full-colour printing, turnaround matters (1-2 days vs 1-3 weeks), or you do not want to hold stock.
Choose screen printing when: you need 100+ identical units, the design is 1-2 colours only, you prioritise the traditional screen-print feel, or you are ordering for a large one-off event where per-unit cost matters.