Digital printing

What is digital printing?

Digital printing is a modern printing method that uses computer technology to transfer high-resolution images directly onto a surface, such as a t-shirt, mug, hat, or tote bag.

Instead of relying on physical plates or stencils, digital printers spray tiny droplets of ink directly onto the material to recreate the design.

This process requires minimal setup, making it cost-effective for both large batches and one-off custom orders. Because of its flexibility, digital printing is a popular choice for print-on-demand businesses. It lets sellers produce and offer personalized products without holding a lot of inventory.

Learn more about Print on Demand and starting a print-on-demand business.

Types of digital printing

Digital printing comes in several forms, each suited for different applications:

• Inkjet and laser printing – The most common forms of digital printing, commonly found in homes and offices. Inkjet uses liquid ink, while laser printing uses toner powder for fast, clean prints.
• Solid ink printing – Often used for larger-scale projects, such as graphic design and marketing materials. It uses a wax-like resin-polymer that produces vibrant, long-lasting colors.
• Digital press printing – Ideal for high-volume orders such as brochures, booklets, labels, and business cards, offering professional quality and fast turnaround times.
• Dye sublimation printing – Uses heat to transfer dye into synthetic fabric or other materials. Popular for custom t-shirts, accessories, and merchandise, sublimation produces durable, vivid prints that won’t crack or peel.
• Digital embroidery – Uses computer-controlled machines to stitch custom embroidery designs directly onto fabric. This method is ideal for creating personalized apparel, uniforms, and promotional items with high precision and consistent quality.

Digital printing process

Digital printing skips plates and transfers, sending your design directly from a computer to the printer. This makes it faster, simpler, and ideal for custom orders.

Step 1 – Prepare the design

• Create or upload the image.
• Remove any digital imperfections and crop to the subject.
• Resize to fit the largest printable area without losing quality.
• Save in a high-resolution, printer-compatible file format.

Step 2 – Print the design

• The printer applies tiny droplets of ink directly onto the material.
• The ink forms a thin layer on the surface, replicating the design in sharp detail.

Step 3 – Set the print

• Heat or curing locks the ink in place for durability.
• The finished product is ready for use, with vivid colors and long-lasting quality.

Digital printing saves time, uses less energy, and produces less waste than more manual printing methods, making it a reliable and eco-friendly choice.

Digital printing machines

Digital printing machines are high-performance printers that create sharp text and images directly from digital files, without the need for plates. This makes them fast, flexible, and ideal for short runs, on-demand jobs, and personalized printing such as brochures, business cards, and labels.

The two main types are inkjet printers, which spray liquid ink for vibrant color and wide-format jobs, and laser/toner printers, which fuse toner to the surface for crisp, consistent results. With minimal setup and the ability to change designs instantly, modern digital presses from brands like HP Indigo, Xerox, and Canon are becoming a top choice for many commercial printing needs.

Digital print media and products

Digital printing works on a wide range of materials, such as:

• Thick cardstock – Greeting cards, business cards, and invitations.
• Folding cartons – Branded packaging or labeled storage boxes.
• Fabric – Custom apparel, tote bags, scarves, and other merchandise.
• Linen – Bed sheets, curtains, bathrobes, and shower curtains.

Its versatility makes digital printing a top choice for producing large quantities of high-quality items at lower costs than traditional printing – from business cards and menus to flyers and newsletters.

Benefits of digital printing

Digital printing offers several advantages over traditional methods:

• Constant innovation – New technologies make it adaptable to more products and creative ideas.
• Lower setup costs – No plates or complex machinery, which reduces maintenance and setup expenses.
• Flexible order sizes – Cost-effective for both single items and bulk runs, perfect for Print on Demand.
• Fast turnaround – Minimal setup steps mean quicker production without sacrificing quality.
• Easy customization – Designs can be edited instantly, making personalized products simple to create.
• Cost-effective black-and-white printing – Even cheaper than color printing while maintaining clarity.

Digital printing vs offset printing

Offset printing is a traditional method where an inked image is transferred (or “offset”) from a printing plate to a rubber blanket, then onto the printing surface. This process works best for large batches – hundreds or thousands of copies – and is ideal when you need exact Pantone colors, specialty inks, or custom paper options.

Digital printing, on the other hand, prints images directly from a computer file onto the material. It’s better for small batches, typically under 100 copies, or when you need a fast turnaround. Digital printing offers high-quality results without the setup time and plate costs required by offset printing.

Conclusion

Digital printing has fast turnaround times, can handle small or large orders, and has high-quality results, making it a versatile choice for everything from apparel and merchandise to packaging and promotional materials. By simplifying production and reducing costs, digital printing continues to lead the way in modern printing solutions.

More on digital printing

• What is sublimation printing?
• What is DTF printing?
• Direct-to-garment printing cheat code