You already know you want custom gear. The part that stalls most orders is picking the decoration method. Screen print, DTF, embroidery, engraving. They all put your logo on something, but they are good at very different jobs, and the wrong choice either costs you money or gives you a result that does not hold up.
This guide is built around your decision, not the machines. We will walk through how to choose by quantity, by what you are decorating, by budget, and by what the gear is actually for. If you want the technical breakdown of how each method works, our decoration methods page covers that in detail. This one is about which to pick.
The 30-second answer
If you only read one thing, read this table. Everything after it is the reasoning.
| Method | Minimum order | Best for | Color handling | Setup fee? |
|---|---|---|---|---|
| Screen print | 25 pieces | Big runs of one design | Up to 6 colors per location | Yes, one-time per design |
| DTF | 1 piece | Small runs, full-color, fine detail | Unlimited color | No |
| Embroidery | 3 pieces | Polos, hats, premium staff wear | Up to 9 thread colors | Yes, one-time digitizing per logo |
| Engraving | 1 piece | Drinkware, tumblers, hard goods | Etched, no color | Yes, one-time per design |
Choose by quantity
Quantity is the single biggest factor, so start here.
Ordering 1 to 2 pieces
Screen print and embroidery are off the table at this size. For apparel, DTF is your method. It has no real minimum, so a single shirt or a one-off sample is fine, and you are not paying to set up screens you will never reuse. For drinkware or hard goods, engraving works at a single piece too.
Ordering 3 to 24 pieces
This is the awkward middle, and it is where most people overpay if they default to screen print. You are still under the 25-piece screen-print minimum, so DTF is usually the right call for shirts and hoodies. If you are doing polos, hats, or anything you want to look premium, embroidery opens up here because its minimum is just 3 pieces.
Ordering 25 or more pieces
Now screen print earns its keep. There is a one-time setup per design, but once the screens are made every additional shirt is cheap, so the per-piece price drops hard as the count climbs. For a team, a school, an event, or a fundraiser running the same one or two designs in volume, nothing beats it on price. Embroidery is still the move at this size if you want stitched logos on polos or caps instead of printed shirts.
Want to see where the numbers actually land for your count? Every product prices each method live as you set quantity, and our pricing guide walks through how the tiers work.
Choose by what you are decorating
The garment matters as much as the count. A method that looks sharp on a tee can look wrong on a polo.
| What you are decorating | Best method | Why |
|---|---|---|
| T-shirts, in volume | Screen print | Cheapest per piece once you clear 25, bold and durable |
| T-shirts, small run or full color | DTF | No minimum, handles photos and gradients screen print can't |
| Polos and button-downs | Embroidery | Stitched logos read as premium and last the life of the shirt |
| Hats and caps | Embroidery | Holds shape and detail on structured headwear |
| Hoodies and crews | Screen print or DTF | Screen print for volume, DTF for small or full-color jobs |
| Tumblers, mugs, hard goods | Engraving | Permanent etched mark, no ink to wear off |
Browse by category if you already know the garment: t-shirts, polos, headwear, and drinkware and engravables.
Choose by budget
Two costs drive the price of a decorated order: the per-piece run cost and any one-time setup.
Screen print, embroidery, and engraving each carry a one-time setup. For screen print and engraving it is a setup per design; for embroidery it is a digitizing fee that converts your logo into a stitch file. That file is reused free on every reorder, so the cost lands once and never again. DTF has no setup, which is exactly why it wins small jobs.
The way to think about it: setup fees are an investment that pays off across volume. On a 200-shirt screen-print run the setup is a rounding error per shirt. On a 6-shirt run it is most of your bill, which is the whole reason DTF exists. Match the method to where your money does the most work, and let quantity decide whether a setup fee is worth absorbing.
Choose by use case
Teams and staff uniforms
For polos and structured caps that need to look professional shift after shift, embroidery is the standard. The 3-piece minimum means even a small crew qualifies, and the stitched finish holds up to repeated washing far better than print. If your team gear is t-shirts in real volume, screen print is the cost-efficient pick.
Events
One design, lots of shirts, a fixed date. That is screen print's home turf once you clear 25 pieces. If your event run is under 25, or you need full-color art like a sponsor logo with a gradient, DTF handles it without a minimum.
Businesses and brands
It depends on the piece. Embroidered polos and caps for a storefront or trade show, screen-printed or DTF tees for giveaways, engraved tumblers for client gifts. Most brand orders end up mixing methods, and that is fine. We run all four in-house, so a mixed order stays under one roof.
Fundraisers
Fundraiser shirts live and die on margin, so the lowest per-piece cost wins. If you can presell into the 25-plus range with a single design, screen print gives you the most money back per shirt. For smaller campaigns or multiple design options, DTF keeps you flexible with no minimum to hit.
The decision matrix
Put it together and most orders resolve in one line.
| If you... | Pick |
|---|---|
| Need 25+ of one design on shirts | Screen print |
| Need under 25, or full-color and detailed art | DTF |
| Want logos on polos, button-downs, or caps | Embroidery |
| Are decorating tumblers, mugs, or hard goods | Engraving |
| Need a single sample or one-off | DTF (apparel) or engraving (hard goods) |
Still on the fence? You can mix methods across one order, and we will send a proof to approve before anything is produced. Everything is made in the USA.
Frequently asked questions
What is the cheapest method for a large order?
Screen print, once you are at 25 pieces or more of the same design. The one-time setup is spread across the run, so the per-piece price keeps dropping as quantity rises.
Can I order just one or two pieces?
Yes. DTF has no minimum for apparel, and engraving has no minimum for drinkware and hard goods. Embroidery starts at 3 pieces and screen print at 25.
Which method lasts the longest?
For apparel, embroidery wins, because the design is stitched into the fabric rather than printed on top, so there is nothing to crack or fade. For drinkware and hard goods, engraving is permanent because the mark is etched into the surface.
Do I have to pay a setup fee?
Screen print, embroidery, and engraving each have a one-time setup. Embroidery's is a digitizing fee that turns your logo into a stitch file and is reused free on reorders. DTF has no setup fee at all, which is why it is the budget pick for small runs.
Can I combine different methods in one order?
Yes. We run screen print, DTF, embroidery, and engraving in-house, so a single order can mix embroidered polos, screen-printed tees, and engraved tumblers. If you are planning a mixed or multi-piece program, reach out and we will help you sort it out. You can also check our FAQ for more on ordering and proofs.