Hybrid Printing vs Screen Printing: Which Is Better for Your T-Shirts?
An honest comparison of hybrid Digital Squeegee printing and traditional screen printing. Same shop, both methods, zero bias.
What Is Traditional Screen Printing?
Traditional screen printing is the oldest and most common method for printing custom apparel. The process uses stencils (called screens) with ink pushed through a fine mesh directly onto fabric. Each color in your design requires a separate screen, which is why screen printing works best for simple designs with 1-8 colors on large production runs.
Screen printing has been the industry standard for decades because it produces vibrant, opaque colors that stand up to repeated washing. The plastisol inks used in traditional screen printing create a thick, bold ink deposit that feels substantial on the garment.
At Print Hybrid, we offer traditional screen printing with a minimum order of 48 pieces. This method excels at producing consistent results for simple logos, text designs, and graphics with solid color areas. Our plastisol inks deliver the bold, opaque colors that screen printing is famous for.
What Is Hybrid Printing?
Hybrid printing is a newer technology that combines the durability of screen printing with the detail and color range of digital printing. Here's how it works: First, a white plastisol base coat is screen printed onto the garment. Then, while that base is still wet, a full-color CMYK image is digitally printed directly onto the wet base using M&R's Digital Squeegee machine equipped with 16 precision print heads.
The result is a print that has the durability of screen printing with the photographic quality of digital printing. Hybrid printing achieves 300 DPI resolution, handles unlimited colors without additional screens, and uses eco-friendly GOTS-certified water-based inks that are free of PVC and heavy metals.
Print Hybrid operates TWO Digital Squeegee machines, making us one of the few shops in the region with this advanced capability. Our hybrid printing minimums start at 72 pieces. For complete details on how this revolutionary technology works, visit our hybrid printing page.
Hybrid vs Screen Printing: Side-by-Side Comparison
| Feature | Traditional Screen Printing | Hybrid Digital Squeegee |
|---|---|---|
| Resolution | 50-60 DPI | 300 DPI |
| Colors | 1-8 per design (each needs a screen) | Unlimited (full CMYK) |
| Minimum Order | 48 pieces | 72 pieces |
| Cost per Shirt (simple design) | Lower for 1-3 colors | Slightly higher |
| Cost per Shirt (complex design) | Higher (more screens = more cost) | Lower (no extra screens needed) |
| Durability | 50+ washes | 50+ washes |
| Hand Feel | Thicker ink deposit | Softer, lighter feel |
| Best For | Simple logos, text, 1-4 color designs | Photos, gradients, full-color artwork |
| Fabric Compatibility | Cotton, cotton blends | Cotton, polyester, blends, fleece |
| Color Consistency | Can shift during long runs | Identical first to last shirt |
| Eco-Friendly | Standard plastisol inks | GOTS-certified water-based inks |
| Special Effects | Puff, metallic, glow (screen only) | Puff, metallic, glow + digital combo |
| Setup | Screens must be burned per color | One screen for white base only |
| Speed | 400-800/hr depending on colors | Up to 600/hr |
When to Choose Traditional Screen Printing
- Your design has 1-3 solid colors with no gradients
- You need the absolute lowest cost per shirt on large runs
- You want thick, bold ink deposit for a vintage feel
- Your order is 48-71 pieces (below hybrid minimum)
- You need specialty inks only (all metallic, all puff)
When to Choose Hybrid Printing
- Your design has photos, gradients, or unlimited colors
- You want 300 DPI photorealistic quality
- Color consistency matters across a large run
- You're printing on polyester or performance fabrics
- You want eco-friendly water-based inks
- You need variable data (names/numbers on each shirt)
Cost Comparison: Hybrid vs Screen Printing
The cost difference between hybrid and traditional screen printing depends entirely on your design complexity. For a simple 2-color logo on 200 shirts, traditional screen printing will almost always be cheaper. For a full-color photographic design with gradients and fine details, hybrid printing is often more affordable because you don't need to pay for 8-12 separate screens.
The break-even point typically occurs around 4-5 colors. Once your design requires more than 4 colors, the cost of burning additional screens in traditional printing often exceeds the flat digital setup fee for hybrid printing.
Both methods have no setup fees at Print Hybrid—you only pay for the actual printing. To get exact pricing for your specific project, contact our team. We'll evaluate your design and recommend the most cost-effective method for your quantity and complexity.
What About DTF Digital Printing?
For orders under 48 pieces or when you need compatibility with any fabric type, DTF (Direct-to-Film) digital printing is your third option. DTF has no minimum order quantity, achieves 720 DPI resolution, and works on any material including polyester, nylon, leather, and even wood.
Learn more about digital printing options or our specific DTF printing services.
Quick Decision Guide
Need 1-47 pieces? → DTF Digital Printing
Need 48-71 pieces, simple design? → Traditional Screen Printing
Need 48-71 pieces, complex design? → Traditional Screen Printing or DTF
Need 72+ pieces, simple design? → Traditional Screen Printing (lowest cost)
Need 72+ pieces, complex/photo design? → Hybrid Digital Squeegee (best quality)
Not sure? → Call us at 806-500-9396 for a free consultation
Hybrid vs Screen Printing FAQ
Both methods last 50+ washes when properly cared for. Hybrid printing uses water-based inks that chemically bond with the plastisol base coat, creating an extremely durable print. Traditional screen printing uses plastisol inks that sit on top of the fabric and cure through heat. Both are extremely durable and will withstand repeated washing, drying, and normal wear.
It depends on your design complexity. Simple 1-2 color designs are cheaper with traditional screen printing. Full-color photographic designs are often cheaper with hybrid printing since you avoid the cost of burning multiple screens. The break-even point is usually around 4-5 colors. Contact us for exact pricing on your specific project.
Yes. Print Hybrid offers traditional screen printing, hybrid Digital Squeegee printing, and DTF digital printing all under one roof. We evaluate each project individually and recommend the best method for your specific design, quantity, budget, and timeline. You get honest advice because we profit from all three methods equally.
Hybrid printing produces a softer hand feel because the water-based CMYK inks absorb into the fabric rather than sitting on top of it. Traditional screen printing creates a thicker, more substantial ink deposit that some customers prefer for the vintage, bold look. Neither is objectively better—it's a matter of preference for your specific application.
Yes. Hybrid printing uses GOTS-certified organic water-based inks that are free of PVC, phthalates, and heavy metals. Cleanup requires only water instead of chemical solvents. Traditional screen printing uses plastisol inks which are PVC-based and require chemical cleanup. If environmental impact is a priority for your brand, hybrid printing is the more eco-friendly choice.
The Digital Squeegee is M&R's patented machine that enables hybrid printing. It combines a traditional screen printing press with 16 high-precision digital inkjet print heads. The screen press lays down the white plastisol base, and the digital heads print full CMYK color onto that wet base in a single pass. Print Hybrid operates two Digital Squeegee machines. Learn more about how it works.
Yes, we ship nationwide. While we're based in Lubbock, Texas, we serve customers across the United States. West Texas customers in cities like Amarillo, Midland, Odessa, and Abilene often receive their orders in 1-2 days. We also serve major metros and remote areas with reliable shipping. Learn more about our regional services.
