A detailed cost analysis comparing DTF and screen printing for a 500‑shirt order (6 colors, front/back) found that DTF was 40% cheaper overall, driven by lower setup costs and reduced labor. The study, conducted by a consulting firm, accounted for screen making, ink mixing, press setup, cleanup, and consumables for screen printing; for DTF, it included film, ink, powder, and heat press time. For a 500‑unit order, screen printing required $280 in setup (screens, registration) and $1.20 per shirt for ink and labor, totaling $880. DTF required $15 in setup (design preparation) and $0.90 per shirt for film/ink/powder and transfer labor, totaling $465. The gap widens as order quantities decrease: for 50 shirts, DTF is 75% cheaper.
The analysis underscores why many small to medium print shops are adding Xinflying DTF printers to their equipment mix. Even for runs up to 1,000 pieces, DTF can be cost‑competitive, especially when artwork has many colors or gradients. However, screen printing remains cheaper for very large runs (over 5,000 pieces) due to its lower per‑unit variable cost. The study also noted that DTF’s lower labor requirement is a significant advantage in markets with high wages. As DTF consumables prices continue to fall, the crossover point is expected to move to even higher volumes, potentially disrupting the traditional screen‑printing model for mid‑range orders.