Digital printing vs offset printing breaks at 750 units—Fioprints.com offers both for custom printing optimization. Print on demand digital crushes t shirt custom printing tests; offset dominates corporate printing solutions catalogs. 2026 tech narrows quality gap 15%, but cost curves diverge sharply.
Digital: Toner/inkjet direct-to-substrate. No plates. Print on demand tshirt files RIP instantly.
Offset: Ink transferred plate→blanket→paper. 6-12hr setup. Corporate folders printing precision.
Key difference: Digital = 1:1 variable data. Offset = identical perfection.
Custom printing on shirts real numbers:
|
Quantity |
Digital Printing (/unit) |
Offset Printing (/unit) |
Winner |
|
100 T shirt print on demand |
$1.85 |
$4.20 |
Digital |
|
500 Corporate sticker printing |
$0.98 |
$1.45 |
Digital |
|
1,000 Print on demand company |
$0.72 |
$0.89 |
Offset |
|
5,000 Corporate banner printing |
$0.58 |
$0.42 |
Offset |
|
25,000 Branded corporate merchandise |
$0.49 |
$0.28 |
Offset |
Break-even: ~750 units. Eco friendly promotional products digital adds 12%.
Print on demand capabilities 2026:
|
Metric |
Digital Printing |
Offset Printing |
Corporate Printing Solutions Winner |
|
Resolution |
2400x2400 DPI |
3500+ effective |
Offset (fine text) |
|
Color Gamut |
92% CMYK |
98% CMYK |
Offset |
|
Registration |
±0.02mm |
±0.005mm |
Offset |
|
Min. Dot Size |
12 micron |
8 micron |
Offset |
|
VDP Capable |
Yes |
No |
Digital |
|
Turnaround |
24-72hrs |
7-14 days |
Digital |
Custom printing on t shirt favors digital speed.
Offset limitations:
✓ 60-450gsm coated/uncoated
✓ Textured/metallic stocks
✗ Heat-sensitive synthetics
✗ Ultra-thin tracing paper
Digital advantages:
✓ Vinyl, synthetics, magnets
✓ Heat transfers (**t shirt custom printing**)
✓ Ultra-thin 40gsm
✗ Heavy 500gsm+ board
Branded business merchandise hybrids solve both.
Print on demand tshirt workflow:
Digital: File→RIP→Print→Finish = **3 days**
Offset: File→Plates→Press setup→Run→Dry = **10 days**
Corporate sticker printing digital: 500/hr. Offset: 18,000/hr (post-setup).
Rush premium: Digital +25%. Offset +75%.
Offset dominates premium:
|
Finish |
Digital |
Offset |
Cost Diff |
|
Spot UV |
Limited |
Full control |
Offset -22% |
|
Foil Stamp |
No |
Yes |
Offset only |
|
Emboss |
No |
Yes |
Offset only |
|
Die Cut |
Yes |
Yes |
Digital +15% |
Custom printing on fabric digital handles basic laminates.
Modern digital presses (HP Indigo, Xerox Iridesse):
Line screen: Digital 175 lpi → Offset 200 lpi
Color density: Digital ΔE 2.1 → Offset ΔE 1.2
Gradient smoothness: Digital 95% → Offset 99%
Human eye difference: <500 units, indistinguishable.
Branded merchandise companies selector:
|
Project |
Quantity |
Deadline |
Winner |
Fioprints.com |
|
T shirt custom printing flyers |
<750 |
<7 days |
Digital |
Print on demand |
|
Corporate folders printing catalogs |
2K+ |
14+ days |
Offset |
Hybrid |
|
Eco friendly promotional products packaging |
Variable |
Rush |
Digital |
Print on demand tshirt |
|
Corporate banner printing annual reports |
5K+ |
Planned |
Offset |
Premium offset |
Print on demand company Fioprints.com:
1. Digital prototypes (100 units)
2. Offset production (1K+ validated)
3. Digital personalization (names/addresses)
4. Offset shells + digital VDP overprint
Cost savings: 28% vs pure offset.
1. Digital printing vs offset printing break-even point?
~750 units for custom printing—digital cheaper below, offset above.
2. T shirt custom printing rush—digital or offset?
Print on demand digital: 24-72hrs vs offset 7+ days.
3. Corporate printing solutions color-critical—offset only?
Modern digital ΔE 2.1 passes 92% brand specs (corporate sticker printing).
4. Eco friendly promotional products—which greener?
Digital: No plates (40% less waste). Offset: Vegetable inks.
5. Branded corporate merchandise VDP needs?
Digital print on demand tshirt only—offset can't personalize.
