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Water-Based vs Plastisol Screenprinting: What’s the Difference?
If you are ordering custom t-shirts, one of the biggest decisions happens before the shirts are even printed.
It comes down to the ink.
Two of the most common methods are water-based screenprinting and plastisol screenprinting. While they can produce similar-looking designs, they perform very differently once worn.
Understanding those differences can help you choose the right option for your shirts.
Feb 28, 2026
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Compare water-based and plastisol screenprinting. Learn how each method feels, wears, and performs to choose the best option for custom t-shirts.
What Is Water-Based Screenprinting?
Water-based screenprinting uses ink that soaks into the fabric rather than sitting on top of it.
Because of that, the print feels soft, lightweight, and breathable.
At Sunday Cool, our Super-Soft Ink is a water-based screenprinting method designed to keep the shirt feeling like a shirt, even after it is printed.
This method is ideal when comfort matters, especially for shirts that will be worn often.
What Is Plastisol Screenprinting?
Plastisol screenprinting uses a thicker ink that sits on top of the fabric.
This creates a more structured, layered print that is easy to see and feel.
It is often used for bold graphics and high-opacity prints, especially on darker garments.
However, because the ink sits on top of the shirt, it can feel heavier and less breathable compared to water-based printing.
The Biggest Difference: How It Feels
This is where the difference becomes obvious.
Water-based screenprinting creates a print that feels soft and natural, almost like it is part of the fabric.
Plastisol screenprinting creates a thicker layer on top of the shirt. That can make the print feel stiff, especially in larger designs or designs with heavy ink coverage.
Over time, plastisol prints can also feel more noticeable with repeated wear.
If you have ever worn a shirt where the design feels like a patch sitting on top, that is typically plastisol.
Breathability and Everyday Wear
Comfort is not just about how a shirt feels at first. It is about how it wears throughout the day.
Because water-based ink blends into the fabric, it allows the shirt to remain breathable.
Plastisol, on the other hand, can trap heat where the design sits. On larger prints, this can make the shirt feel warmer and less comfortable over time.
For shirts that are meant to be worn often, especially in warm environments, this difference matters.
How They Age Over Time
Both printing methods are durable, but they age differently.
Plastisol prints tend to hold their shape, but over time they can crack or peel, especially if the print is thick.
Water-based prints age more naturally. Because the ink is part of the fabric, it softens with the shirt rather than separating from it.
Many people prefer this worn-in look because it keeps the shirt feeling comfortable even after repeated washes.
Which One Should You Choose?
Both methods have their place, but for most custom t-shirts, water-based screenprinting is the better choice.
If your goal is to create something that people will actually wear again and again, comfort matters.
Water-based printing delivers:
a softer feel
better breathability
a more natural look over time
Plastisol can still work for very bold or highly saturated designs, but for everyday wear, it is often not the preferred option.
Why We Focus on Water-Based Printing
At Sunday Cool, we have spent years refining what makes a great custom t-shirt.
One of the biggest factors is how it feels.
That is why we use water-based screenprinting through our Super-Soft Ink. It allows us to create shirts that look great, feel comfortable, and hold up over time.
Because in the end, the best shirt is the one people keep wearing.
Beyond Ink: Specialty Finishes That Stand Out
In addition to our Super-Soft Ink, we also offer a range of Specialty Inks that create unique, interactive designs.
These specialty options can add another layer of creativity while still maintaining the comfort and quality of our printing process.
Ready to Get Started?
If you are looking for custom t-shirts with a soft, high-quality print, we are here to help.
👉 Ready to Get Started? Start your custom order HERE
People Also Ask
What is the difference between water-based and plastisol screenprinting?
Water-based screenprinting soaks into the fabric, creating a soft, breathable print. Plastisol screenprinting sits on top of the fabric, resulting in a thicker, more noticeable layer.
Which screenprinting method is softer?
Water-based screenprinting is softer because the ink blends into the fabric instead of forming a layer on top.
Does plastisol ink crack over time?
Plastisol ink can crack or peel over time, especially with heavier prints. Water-based prints tend to wear more naturally with the fabric.
Which is better for custom t-shirts?
For most custom t-shirts, water-based screenprinting is the better choice because it provides a softer feel, better breathability, and more comfortable long-term wear.
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"Your Logo Here" has never looked so good - let us guide the way.
Thanking a big team on a budget? Go with a custom ornament.
Want something wearable? The beanie is the sweet spot.
Thanking your key leaders or staff? Go cozy with a hoodie or blanket.
Custom Leatherette Ornaments
New this season, and a great fit for church Christmas gifts and volunteer thank-yous. Each ornament has a rich leather-look finish, stitched edges, and a gold hanging string, so it’s tree-ready out of the box. Your design or logo is printed in full-color Digital Ink, so every detail stays crisp and bright.
Order basics: 12-piece minimum and a $40 setup fee. Prices start at $4.87 each for a front-only print, and drop as your quantity grows. Want both sides? A front-and-back print is available. Each product page has ready-to-customize templates, so you can personalize one in minutes.
Great for: big volunteer teams, a keepsake they’ll pull out every December, adding your church name and year
Cuff Beanie w/ Leatherette Patch
A gift volunteers actually wear. The Cuff Beanie w/ Leatherette Patch puts your logo on a custom leatherette patch (square, rectangle, or circle, up to 3" x 2").
Order basics: 12-piece minimum, 72-hour turnaround, and a $0 setup fee. Pricing starts around $8 each at larger quantities. Check the product page for exact tiers.
Great for: small group leaders, worship teams, serve teams that work outdoors
Super-Soft Hoodie
For your core leaders, give something they’ll reach for all winter. The Super-Soft Hoodie comes in six colors, including our newest, Cocoa, and Sand.
Order basics: 12-piece minimum for a one-color, one-location design and a 72-hour turnaround.
Great for: staff, key volunteers, leaders who give the most
Super-Soft Fleece Blanket
Looking for the gift that says “rest up, you earned it”? The Super-Soft Fleece Blanket is a cozy keepsake for a pastor, a longtime volunteer, or anyone who needs a break.
Great for: staff, retiring volunteers, a “go big” thank-you
Make It Personal
The best volunteer gifts feel like they were made for your team. A few ideas:
Add the year and a verse. A dated ornament becomes a tradition.
Pair it with a handwritten note. A short thank-you turns a nice gift into a memorable one.
Give it a moment. Hand them out at a volunteer dinner or a Sunday-morning shout-out.
Match your look. Pull your church colors or logo across every piece so it feels cohesive. Our church merch guidecovers how.
Plan Your Timeline
Gifts have a deadline, and the ornaments have different turnarounds:
Round Leatherette Ornament: 4 days
Tree Leatherette Ornament: 2 weeks
Cuff Beanie and Super-Soft Hoodie: 72 hours after art approval
Build in time for design approval and shipping. For a mid-December volunteer dinner, we’d start the Tree Leatherette Ornament by mid-November and everything else by early December.
People Also Ask
What are good volunteer appreciation gifts for church? Small, thoughtful, personalized gifts work best. Custom ornaments, a beanie, a hoodie, or a fleece blanket all give volunteers something to keep.
What is the minimum order for custom leatherette ornaments? 12 pieces for both the Round Leatherette Ornament and the Tree Leatherette Ornament.
How long do custom ornaments take? The round ornament has a 4-day turnaround and the tree ornament takes 2 weeks, plus shipping time.
Can I put our church logo or a verse on the ornament? Yes. Your design or logo prints in full-color Digital Ink, and ornament templates are available on each product page.
What’s a good gift for staff or key leaders? A Super-Soft Hoodie or Super-Soft Fleece Blanket is a cozy way to say thanks to the people who give the most.
Your volunteers give a lot. A small, thoughtful gift tells them you see it.
Want your hoodie to stand out from every other group’s? Puff Ink adds raised, textured detail to a logo or key word, and it’s a favorite pairing for fleece.
Everything else prints with Super-Soft Ink, our water-based ink that soaks into the fabric instead of sitting on top, so the print stays soft and breathable. Water-based ink gives hoodies a muted, vintage look. Our Guide to Understanding Water-Based Print Results explains what to expect.
Ordering Youth Group Hoodies: What to Know
Minimum order: 12 pieces for a one-color, one-location design. 36 pieces for multiple colors or locations.
Turnaround: 72 hours after art approval
Setup fee: $15 per screen
Same design across the order: every piece in one order shares the same artwork, and youth and adult sizes can ride together.
Timeline tip: start 4–6 weeks before your event. Design and sizing take longer than printing, and a 72-hour turnaroundonly helps once your art is approved.
Sizing tip: collect sizes early and tell students the hoodie runs regular. If they like a relaxed fit, they should size up.
Keep Them Soft for Years
Pass this on to your students and parents:
Wash inside out, on cold and gentle
Skip the bleach
Add fabric softener to keep the softness (and prevent piling)
People Also Ask
What is the best hoodie for a youth group? A soft, regular-fit pullover that holds up to repeat wear. The Super-Soft Hoodie is made for group merch, camps, retreats, and DNOW weekends.
Should we order hoodies or crewnecks for our youth group? Hoodies give you the most warmth and the most print placements, including the hood-side details and a sleeve print. The Super-Soft Crewneck is a clean, hood-free option that works well for leaders, volunteers, or groups that want a more polished look.
What is the minimum order for custom hoodies? 12 pieces for a one-color, one-location design, and 36 pieces for multiple colors or locations.
How long does it take to get custom youth group hoodies? Turnaround is 72 hours after art approval. Plan on starting the design and sizing process 4–6 weeks before your event.
What size hoodies should we order for our group? Collect sizes from your students and let them know the fit is regular. A roomier look means sizing up.
Can we mix youth and adult sizes in one order? Yes, as long as the whole order uses the same artwork.
Hoodies are the layer students reach for when the weather turns. Make yours one they’re proud to wear.
All November long, Sunday Cool is offering free standard ground shipping on qualifying fleecewear orders. That means more of your budget goes toward the gear your group will actually wear, whether it’s for a winter retreat, a Christmas gift for your team, or matching hoodies for your student ministry.
What Fleece Qualifies?
This promo covers our two cool-weather favorites:
Super-Soft Hoodie: our go-to layer for cold nights, early mornings, and everything in between.
Super-Soft Crewneck: a clean, classic fit that’s just as comfortable as it looks.
Terms and Conditions
More than 50% of your total order quantity must be inventoried fleece.
Eligible fleece is limited to our Super-Soft Hoodies and Crewnecks.
Includes standard ground shipping only.
Valid for orders shipping to one address.
Cannot be combined with any other discounts or promotions.
Order must be invoiced by November 30, 2026.
Free shipping cannot be applied after an order has been invoiced.
People Also Ask
Can I include tees or other items in my order? Yes, as long as more than half of your total order quantity is Super-Soft Hoodies or Crewnecks.
Does free shipping include rush or expedited shipping? No. This promotion covers standard ground shipping only.
Can I ship my order to multiple locations? Free shipping applies to orders shipping to one address.
Can I use this with another Sunday Cool discount? No. This offer can’t be combined with any other discounts or promotions.
What if my order has already been invoiced? Free shipping can’t be added after invoicing, so make sure your order qualifies before it’s finalized.
Hoodie weather doesn’t wait, and neither does this deal! Get your order invoiced by November 30, 2026 to make it count.
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