Beyond the Digital Hype - Strategic Implementation of DTF/DTG Business

The analog screen printing industry is shifting as digital technologies Direct-to-Film (DTF) and Direct-to-Garment (DTG) gain traction. Mark Coudray provides a practical roadmap for established screen printers to assess, implement, and communicate the value of these technologies while managing customer expectations.

The analog screen printing industry is shifting as digital technologies Direct-to-Film (DTF) and Direct-to-Garment (DTG) gain traction. This article provides a practical roadmap for established screen printers to assess, implement, and communicate the value of these technologies while managing customer expectations.

Understanding the Evolution of Printing Technologies

Every innovation follows a predictable adoption path. Early adopters experiment with new technologies, often tolerating inefficiencies to gain competitive advantages. As the technology evolves, it becomes more reliable, cost-effective, and widely embraced by the mainstream market. Pricing becomes more commoditized. Screen printers must navigate strategically, balancing  benefits of early adoption against risks of untested processes.

The Shift from Analog to Digital

History shows once digital processes enter a space, analog methods rarely survive. Film photography gave way to digital cameras; vinyl records were eclipsed by streaming services (though they’ve found niche resurgence). Similarly, while traditional screen printing will persist for specific applications while digital DTF and DTG are poised to dominate due to their flexibility, speed, and cost-effectiveness for small runs.

Why Consider DTF/DTG?

DTF and DTG present clear advantages for screen printers:

• Flexibility: Both methods handle small orders and complex designs that are cost-prohibitive with screen printing. Important because digital is the unit of ONE vs analog where the economies are at volume.

• Speed: Digital printing eliminates setup steps like creating screens or mixing inks, but are much slower to produce on a per hour unit volume. The savings are in design changeover

• Customization: Personalization at scale becomes feasible, meeting growing consumer demand for unique products. This is what is driving the Print on Demand (POD) market.

• Material Versatility: DTF prints on diverse substrates—cotton, polyester, leather—offering broader product options.

These benefits come with challenges: higher per-unit costs for large runs, potential differences in print texture compared to traditional methods, and the need for customer education.

A Roadmap for Decision-Making

1. Evaluate Your Current Offerings
Start by analyzing your business model and customer base:

• Order Patterns: Are you turning away small orders because they’re unprofitable with screen printing? Do clients request complex designs or specialty placements (e.g., sleeves or neck labels)?

• Customer Expectations: Are your buyers demanding faster turnaround times or more customization?

• Competitive Landscape: Are competitors offering digital printing options that you lack?

If these trends align with your business challenges, DTF/DTG may fill critical gaps.

2. Start Small: Outsource Before Investing
For businesses new to digital printing, outsourcing DTF transfers is a low-risk entry point. This allows you to test customer demand and various feel differences without committing to equipment purchases.

As demand grows and you gain confidence in the process, invest in entry-level DTF or DTG systems. These systems integrate well with existing workflows and enable on-demand production.

3. Match Technology to Job Requirements
Choosing between screen printing, DTF, and DTG depends on factors like order size, design complexity, and material type:

Factor	Screen Printing	DTF	DTG
Order Size	Best for large runs (100+ items).	Ideal for small-to-medium runs.	Best for one-offs or very small runs.
Design Complexity	Spot color & Halftone images	Intricate CMYK multi-color designs	Photographic CMYK & highly detailed designs.
Material Compatibility	Most fabrics; requires prep work for synthetics.	Works on cotton, polyester, nylon.	Best on cotton and light blends.
Cost Efficiency	Low cost per unit at scale.	Mid-range costs; no setup fees.	Higher per-unit costs; minimal setup time.

For example:

• Use screen printing for bulk orders.

• Leverage DTF for specialty placements (e.g., sleeve prints) or multi-material projects.

• Offer DTG for personalized items or high-detail artwork.

4. Communicate Clearly with Customers
Digital prints differ in feel and appearance from traditional screen prints—DTF feels thicker and more like a plastic layer due to its white underbase and adhesive. DTG can offer a softer finish but only on certain fabrics. Avoid surprises by proactively managing expectations. This builds trust and reduces dissatisfaction.

• Educate Buyers: Explain and show the differences between print methods upfront.

• Set Expectations: Highlight benefits like faster delivery times or expanded design options while addressing texture differences.

• Showcase Samples: Provide physical samples so customers can see and feel the results before committing.

5. Plan for Long-Term Integration
As your confidence in digital processes grow:

• Invest in higher-capacity equipment to handle larger volumes efficiently.

• Train staff on color management and maintenance procedures.

• Explore hybrid workflows—e.g., combining screen printing for bulk orders with DTF/DTG for personalization.

Economic Advantages for End Buyers

One of the strongest arguments for adopting DTF/DTG is the economic benefit it provides to your customers:

1. Reduced Inventory Costs: With on-demand production, buyers can order only what they need—no more stockpiling unsold inventory.

2. Customization Without Premiums: Digital methods enable affordable personalization at scale.

3. Fast Turnaround Times: Meet tight deadlines without sacrificing quality.

4. Access to Specialty Applications: Offer unique placements (e.g., sleeve & neck labels) that were previously cost-prohibitive.

Framing these benefits in client conversations positions you as a forward-thinking partner who delivers value beyond traditional methods.

The Inevitable Transition: Analog vs Digital

While screen printing will retain niche appeal—similar to vinyl records—the future belongs to digital technologies. Younger generations entering the workforce and consumer preferences are evolving toward customization and immediacy.  Businesses failing to adapt risk obsolescence.

This transition won’t happen overnight:

• Use digital methods as a supplement rather than a replacement initially.

• Gradually shift resources toward high-demand digital applications.

• Monitor industry trends to stay ahead of competitors.

Embrace Change Strategically

The adoption of DTF/DTG isn’t just about keeping up with trends—it’s about future-proofing your business in an increasingly digital world. By following this roadmap:

1. Evaluate your current offerings against market demands.

2. Start small by outsourcing or investing incrementally.

3. Match technology to project requirements strategically.

4. Communicate openly with customers about what they can expect.

5. Plan for long-term integration as digital processes become mainstream.

Ultimately, embracing innovation positions your business not only as a service provider but as a trusted transformation partner capable of meeting changing demands efficiently and creatively.

Profit Maximization Strategies

To maximize profitability with DTF, consider implementing tiered pricing structures based on quantity, design complexity, and turnaround time. The substantially lower setup costs of DTF allow competitive pricing on smaller orders while maintaining healthy margins. For instance, small transfers ("x") might range from $ each for - pieces to $0.0 each for 0+ pieces.

Gang sheets represent another significant cost-saving opportunity. By arranging multiple designs on a single sheet, businesses can reduce the per-transfer cost substantially, passing savings to customers while maintaining margins. This approach works particularly well for recurring clients with multiple small designs.

Digital Workflow Integration

Modern DTF systems thrive on seamless digital workflow integration, transforming traditional production methods into streamlined, data-driven processes that maximize efficiency and minimize errors. Investing in software to support file preparation systems, advanced job queuing capabilities, and real-time production tracking creates a foundation for scalable, efficient operations regardless of which printing technology is deployed for specific jobs.

Conclusion

The most successful print businesses aren't choosing between traditional and digital methods—they're creating integrated workflows that leverage the strengths of each technology. This isn't about abandoning traditional methods—it's about expanding capabilities to serve a broader range of customer needs profitably.

The accessibility of DTF printing, offers evolutionary opportunities for businesses to enhance their offerings without prohibitive investment. From specialized applications like sleeve printing and neck labels to flexible production of small orders and complex designs, DTF fills critical gaps in the traditional screen printing model while complementing its strengths.

Today, success belongs to those who view diverse technologies not as competitors but as complementary tools in an expanding arsenal of solutions for customers' evolving needs.

Discover the latest innovations in screen printing, DTF and DTG printing at FESPA Global Print Expo 2025, Europe's leading print and signage exhibition taking place from 6 - 9 May at Messe Berlin, Germany. It will showcase the most innovative products, visionary concepts, and latest developments in the future of print. Register to visit here and use promo code FESJ503 and only pay 50 euros for your ticket.