Why the Best Printing Methods for Bulk T-Shirt Orders Are Still Screen Printing

When you’re ordering hundreds (or even thousands) of t-shirts, choosing the right printing method is a big decision. You want quality that lasts, a price that makes sense, and prints that look just as good on shirt #1 as they do on shirt #1,000. While digital printing and heat press have gained popularity for small runs and niche uses, custom apparel screen printing continues to lead the pack for large-scale production.

In this blog, we’ll break down why screen printing remains one of the best printing methods for bulk t-shirt orders and why so many businesses and teams stick with it.

What Makes a Printing Method “Best” for Bulk?

Before diving into comparisons, let’s define what “best” really means when it comes to bulk t-shirt printing. For large orders, you’re typically looking for:

Cost-efficiency per piece
Consistent, high-quality output
Durability through wash and wear
Scalability across hundreds or thousands of garments

Screen printing checks all of these boxes for large orders for t-shirts. It’s been the go-to method for decades for a reason: once the screens are set up, it runs fast and produces excellent results at volume.

Why Screen Printing Still Reigns Supreme

Screen printing uses stencils (screens) and layers of ink to transfer your design onto fabric. While setup takes a bit more time compared to digital options, once it’s ready, the process is built for speed and accuracy, which is perfect for bulk jobs.

Cost-Effective at Scale

One of the biggest reasons screen printing is among the best printing methods for bulk t-shirt orders is cost. Though setup costs are higher than digital printing, those costs are spread over each shirt in the order. That means the more shirts you print, the lower your cost per unit. If you’re printing 100 or more shirts, screen printing will almost always be the most affordable method.

Exceptional Print Quality

Screen printing delivers bold, opaque colors with sharp edges and strong contrast. It works especially well for logos, large graphics, or simple designs where color clarity matters. Inks used in screen printing are thicker than digital prints, which helps them stand out better, especially on dark fabrics. For brands that want their design to pop and last, this method still wins.

Long-Lasting Durability

Printed t-shirts go through a lot: laundry, wear, stretching, heat, etc. Screen-printed designs are known for holding up over time. They don’t peel or fade as quickly as digital prints might. If your shirts are going to be worn again and again, say, for a sports league, company uniform, or fundraising campaign, you want something that’s going to last.

When it comes to the best printing methods for bulk t-shirt orders, screen printing continues to set the standard, and we’re proud to lead the way. Marathon Sportswear offers fast turnaround times, dependable quality, and hands-on support for every order.

Our Screen Printing Process

How Does the Screen Process Compare to Other Printing Methods?

Let’s look at how screen printing stacks up against other popular printing techniques.

Screen Printing vs. Digital Printing

Best for: Small batches or complex, multicolor designs with gradients
Pros: No setup time; full-color capability
Cons: Slower for large batches, colors may fade more quickly, especially on dark fabrics

Digital printing is great for single-shirt orders or custom one-offs, but once you start scaling up, screen printing is faster and more affordable.

Heat Transfer

Best for: Personalization like names or numbers
Pros: Great for short runs and specialty prints
Cons: Less durable, can crack or peel over time

Heat transfers are useful in specific situations but usually not ideal for bulk orders due to their labor-intensive nature and shorter lifespan.

Partner With Marathon Sportswear for the Best Bulk Screen Printing in Chicago

Marathon Sportswear knows bulk printing better than anyone. Our screen printing team delivers the vibrant color, crisp detail, and long-lasting quality you need, on time and within budget. If you’re looking for the best printing methods for bulk t-shirt orders, you’ve found your match. Get in touch for a quote and let’s start printing.