Printing on apparel is more than just adding a logo or design. It’s about creating high-quality, durable, and visually striking products that represent your brand. At Flywheel Brands, we know the right printing method can make or break your project, whether you’re producing uniforms, event apparel, or custom merchandise.

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In 2025, printing technology has evolved to give brands more options than ever. From traditional screen printing to advanced digital techniques, each method has strengths and limitations. Understanding these differences ensures your designs look their best, last longer, and meet your budget and production needs.

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This guide breaks down the main types of printing on fabric and clothes, what makes each one unique, and which techniques are the most effective for 2025.

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Introduction: Printing on Fabric and Clothes in 2025

Printing technology is no longer one-size-fits-all. Every method affects durability, detail, and production speed differently. Choosing the right option depends on several factors:

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• The type of fabric you are printing on
• Order size and budget
• Complexity and color of the design
• Environmental considerations

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Flywheel Brands works with clients to match their vision with the most suitable printing technique. In 2025, advancements in both digital and traditional methods allow for higher resolution, more color options, and sustainable ink choices.

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Screen Printing: Reliable and Long-Lasting

Screen printing has been around for decades and remains a reliable choice for high-volume orders. It uses stencils, called screens, to apply layers of ink to fabric. Each color is applied separately, creating bold and vibrant designs.

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Why it works in 2025:
Screen printing is still preferred for large runs because it produces durable designs that hold up through repeated washing. It’s cost-effective when producing hundreds or thousands of items with simple graphics.

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Pros:

• Bold, vibrant colors
• Extremely durable and long-lasting
• Cost-efficient for bulk orders

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Cons:

• Not ideal for intricate or photo-quality designs
• High setup costs for small batches
• Less environmentally friendly than newer digital methods

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Best for: Work uniforms, branded t-shirts, and bulk promotional apparel.

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Digital Printing (DTG): High-Resolution Detail

Direct-to-garment (DTG) printing applies ink directly to the fabric using specialized printers, similar to an inkjet printer on paper.

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Why it’s trending in 2025:
DTG allows for highly detailed, full-color designs with gradients and complex graphics. Modern water-based inks make this method eco-friendlier than ever. It is perfect for brands offering custom apparel or small batch production.

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Pros:

• High-resolution, photo-quality prints
• Ideal for small or custom orders
• No setup fees for different designs
• Uses environmentally safe inks

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Cons:

• Works best on cotton or cotton-blend fabrics
• Not as durable as screen printing for heavy-use apparel
• Slower for large-scale orders

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Best for: Custom t-shirts, print-on-demand merchandise, and limited-edition designs.

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Heat Transfer Printing: Flexible and Colorful

Heat transfer printing uses special transfer paper to apply a design to fabric with heat and pressure.

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Why it’s popular in 2025:
Advancements in transfer films and inks have made heat transfer more durable. This method is especially useful for smaller runs and complex, multi-color designs.

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Pros:

• Works well for small batches
• Can handle intricate, multi-color designs
• Perfect for personalized sportswear

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Cons:

• Prints may crack or peel over time
• Adds weight to the garment
• Not as long-lasting as sublimation or screen printing

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Best for: Jerseys, promotional apparel, and limited-edition custom designs.

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Dye Sublimation: Seamless and Permanent

Sublimation uses heat to embed dye directly into polyester fibers, creating a print that becomes part of the fabric.

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Why it’s standing out in 2025:
Sublimation allows for full-coverage designs without adding weight or texture. It produces long-lasting, vibrant prints that are ideal for activewear and event apparel.

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Pros:

• Permanent, fade-resistant designs
• Smooth, lightweight prints
• Allows for edge-to-edge, full garment designs

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Cons:

• Only works on polyester and light-colored fabrics
• Small orders can be more costly
• Not suitable for cotton fabrics

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Best for: Sportswear, custom fashion apparel, and event gear with full-coverage graphics.

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Vinyl Printing: Bold Graphics and Lettering

Vinyl printing uses heat to transfer cut-out vinyl designs onto apparel. It is especially popular for lettering, numbers, and simple logos.

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Why it’s still useful in 2025:
Vinyl remains a go-to method for uniforms, sportswear, and work apparel. Specialty finishes like metallic or glitter vinyl add visual interest for branded designs.

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Pros:

• Long-lasting and durable
• Clean and bold graphics
• Specialty finishes available

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Cons:

• Limited to simple shapes or lettering
• Adds texture to the fabric
• Not practical for complex or large-scale designs

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Best for: Team jerseys, corporate uniforms, and bold branded apparel.

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Block Printing: Handmade and Sustainable

Block printing is an artisanal method where carved wooden blocks are dipped in ink and stamped onto fabric.

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Why it’s niche but valued in 2025:
Although slow and labor-intensive, block printing is appreciated for small, sustainable collections and one-of-a-kind designs.

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Pros:

• Unique, handmade look
• Eco-friendly with natural dyes
• Works for small-batch custom apparel

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Cons:

• Time-consuming and not scalable
• Limited design complexity
• Less consistent than modern methods

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Best for: Boutique fashion, artisan collections, and sustainable apparel lines.

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Rotary Screen Printing: High-Volume Fabric Printing

Rotary screen printing uses cylindrical screens to print on fabric rolls. It is a mainstay for large-scale textile production.

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Why it matters in 2025:
This method is ideal for bulk production, offering speed and consistency while still delivering vibrant results.

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Pros:

• Efficient for long runs of fabric
• Durable and vibrant prints
• Cost-effective for high-volume projects

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Cons:

• High initial setup costs
• Uses more water and chemicals
• Not practical for short or custom orders

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Best for: Fashion fabrics, home textiles, and large-scale apparel production.

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Hybrid Printing: Durability Meets Detail

Hybrid printing combines screen printing for durability with digital printing for detail. This technique allows brands to get the best of both worlds.

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Why it’s growing in 2025:
Hybrid printing is ideal for brands that want long-lasting prints without sacrificing complex design quality.

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Pros:

• Combines durability and detail
• Efficient for medium-sized orders
• Bright, high-resolution results

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Cons:

• Requires specialized equipment
• More expensive than single-method printing

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Best for: Branded apparel, promotional products, and projects requiring both quality and detail.

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Choosing the Best Printing Method in 2025

The right choice depends on your goals:

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• Bulk orders and simple graphics: Screen printing
• Detailed, photographic designs: Digital printing or hybrid
• Edge-to-edge polyester designs: Sublimation
• Small, sustainable, or artisan collections: Block printing
• Durable team or work apparel: Vinyl printing

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Digital methods, particularly DTG and sublimation, are the most versatile for 2025. They balance customization, sustainability, and high-quality results, making them ideal for modern brands and promotional programs.

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How Flywheel Brands Helps

At Flywheel Brands, we guide clients through every step of apparel production. Choosing the right printing method ensures your designs look professional, last long, and reflect your brand values. Whether you’re producing uniforms, event apparel, or custom merchandise, we match your vision with the best technology and materials available.

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Conclusion

Printing on fabric and clothes has never offered more options. Each technique has strengths, from the bold durability of screen printing to the fine detail of DTG and the seamless, edge-to-edge results of sublimation. Understanding these differences helps you make informed decisions that enhance your brand and ensure long-lasting, high-quality apparel.

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In 2025, digital printing methods lead the way, but traditional techniques like screen, vinyl, and block printing still have an important role. Flywheel Brands helps you choose the right approach, so your projects look great, feel professional, and leave a lasting impression. Contact us today to get started on your project!