Hybrid Printing vs DTG Printing: Why Hybrid Wins
DTG fades after a few washes. Hybrid printing delivers production speed, fabric versatility, and durability that DTG can't match.
What Is Hybrid Printing?
Hybrid printing uses M&R's Digital Squeegee to combine screen printing and digital inkjet into one process. A white plastisol base coat is screen printed onto the garment, then while the base is still wet, full-color CMYK artwork is digitally printed at 300 DPI directly on top using 16 industrial inkjet heads.
The plastisol base creates a durable foundation that bonds to the fabric, and the water-based digital inks bond chemically to the plastisol. This two-layer system produces prints that last 50+ washes without fading or cracking, while delivering unlimited colors and photorealistic detail.
Print Hybrid operates two Digital Squeegee machines with a 72-piece minimum order. Learn more on our hybrid printing page.
What Is DTG Printing?
DTG (Direct-to-Garment) printing works like a large inkjet printer that sprays water-based ink directly onto fabric. The garment must first be pretreated with a chemical solution that helps the ink adhere, then heat-cured after printing.
DTG is popular for on-demand printing and small orders because there's no screen setup. However, the pretreatment process creates a weak bond between ink and fabric, which is why DTG prints typically begin to fade and crack after just 10-15 washes. DTG is also limited to 100% cotton fabrics — it doesn't work on polyester, poly-blends, or fleece.
Hybrid vs DTG Printing: Side-by-Side Comparison
| Feature | Hybrid (Digital Squeegee) | DTG (Direct-to-Garment) |
|---|---|---|
| Wash Durability | 50+ washes | 10-15 washes before fading |
| Fabric Compatibility | Cotton, polyester, blends, fleece | 100% cotton only |
| Resolution | 300 DPI | 1200 DPI |
| Colors | Unlimited (CMYK) | Unlimited (CMYK) |
| Production Speed | Up to 600/hr | 10-30/hr |
| Pretreatment Required | No | Yes (chemical spray) |
| Minimum Order | 72 pieces | No minimum |
| Hand Feel | Soft, ink bonds to plastisol base | Soft initially, degrades with washing |
| Ink Type | GOTS-certified water-based on plastisol | Water-based on pretreated fabric |
| Cost (72+ pieces) | Lower per unit | Higher per unit |
| Cost (under 72 pieces) | Not available | Lower (no screen setup) |
| Special Effects | Pantone matching, puff, metallic, glitter | Standard CMYK only |
| Eco-Friendly | GOTS-certified, PVC-free, water cleanup | Water-based inks but chemical pretreatment |
| Best For | 72+ pcs, any fabric, production runs | 1-off cotton prints, on-demand |
Where Hybrid Printing Beats DTG
Wash Durability
This is the biggest difference. DTG prints rely on a chemical pretreatment to hold ink on the fabric surface. After several washes, that pretreatment breaks down and the print fades, cracks, or peels. Hybrid printing uses a screen-printed plastisol base coat — the same durable foundation used in traditional screen printing for decades — giving hybrid prints 50+ wash durability.
Fabric Versatility
DTG only works on 100% cotton. That rules out polyester jerseys, tri-blends, performance wear, and fleece — all popular fabrics for custom apparel. Hybrid printing works on cotton, polyester, poly-blends, and fleece, opening up options for athletic teams, corporate uniforms, and outdoor apparel.
Production Speed
The Digital Squeegee prints up to 600 garments per hour. A typical DTG printer handles 10-30 per hour. For orders of 72+ pieces, hybrid printing isn't just faster — it's an entirely different category of throughput. This speed advantage also translates to lower per-unit costs on larger orders.
Special Effects
Need an exact Pantone color match? Want puff ink, metallic, or glitter effects? Hybrid can combine screen-printed special effects with digital artwork in the same print. DTG is limited to standard CMYK output.
When to Choose Hybrid Printing
- You need 72+ pieces for a production run
- Wash durability matters (uniforms, merchandise, resale)
- You're printing on polyester, blends, or fleece
- Your design has complex multi-color or photographic artwork
- You need consistent color across every piece in the run
- You want Pantone matching or special effects (puff, metallic)
When DTG Still Makes Sense
- You need just 1-5 pieces (samples, gifts, prototypes)
- You're printing on 100% cotton only
- Long-term durability isn't a priority
- You need on-demand or print-on-demand fulfillment
For small orders where DTG's limitations are acceptable, consider our DTF printing instead — it offers similar flexibility with better durability and works on any fabric.
Quick Decision Guide
Need 72+ pieces on any fabric? → Hybrid Digital Squeegee
Need under 72 pieces? → DTF Digital Printing (better than DTG)
Need special effects? → Hybrid Digital Squeegee
Need prints that last 50+ washes? → Hybrid Digital Squeegee
Printing on polyester or fleece? → Hybrid or DTF (DTG won't work)
Not sure? → Call us at 806-500-9396
Hybrid vs DTG Printing FAQ
DTG relies on a chemical pretreatment sprayed onto the fabric before printing. This pretreatment helps ink adhere to the surface, but it breaks down over repeated wash cycles. As the pretreatment degrades, the ink loses its bond and begins to fade, crack, or peel. Hybrid printing avoids this entirely by using a screen-printed plastisol base coat that physically bonds to the fabric fibers.
No. Standard DTG printing only works on 100% cotton garments. The water-based DTG inks and pretreatment process are designed specifically for cotton fibers. If you need prints on polyester, poly-blends, fleece, or performance fabrics, hybrid printing or DTF are the right options. Print Hybrid's Digital Squeegee handles all of these fabrics.
For orders of 72+ pieces, hybrid printing is typically less expensive per unit than DTG because of its production speed (600/hr vs 10-30/hr). The higher throughput means lower labor cost per garment. Hybrid does require a 72-piece minimum, so for very small orders (under 72), DTG or DTF may be more practical — though we recommend DTF over DTG for its superior durability.
Print Hybrid does not offer DTG printing because we believe DTF is a better option for small orders. DTF works on any fabric (not just cotton), lasts longer than DTG, and produces comparable color quality. For larger orders (72+ pieces), our hybrid Digital Squeegee printing delivers superior results in every category. We offer honest recommendations based on what's best for each project.
DTG achieves higher DPI (1200 vs 300), but DPI alone doesn't determine print quality. Hybrid printing produces vibrant, photorealistic results with consistent color across every piece in a run. The visual difference between 300 DPI and 1200 DPI is minimal on fabric at normal viewing distance. Where hybrid clearly wins is longevity — the print looks just as good after 50 washes as it did on day one.
