T-Shirt & Merchandise

T-Shirt & Merchandise — questions and answers

What's the maximum number of colours for screen printing and why does it matter?

Screen printing typically uses one to six spot colours, with each colour requiring a separate screen and press pass. More colours increase production complexity and setup time. Designs with gradients or photographic elements need simulated process printing (CMYK) or direct-to-garment methods instead. Simple, bold designs with fewer colours often print more reliably and economically.

How does garment colour affect design decisions?

Dark garments require an underbase layer of white ink so colours appear vibrant, which adds thickness and affects how fine details print. Light garments allow transparent inks and finer detail. Designs must be adapted for both if printing on mixed garment colours, sometimes requiring separate file versions with adjusted stroke weights or colour choices.

Why do some designs work for t-shirts but not embroidery?

Embroidery uses thread thickness that can't reproduce fine lines, small text below 6mm height, or intricate detail. Gradients are impossible; shading requires stitch direction changes or fill patterns. Designs need simplified shapes, thicker strokes and higher contrast. Very small elements that print clearly will disappear or blob when stitched.

What resolution and dimensions should artwork be prepared at?

Vector artwork (AI, EPS, PDF) scales infinitely and is preferred for most printing methods. Raster artwork for direct-to-garment or full-colour transfers needs 300 DPI at the final printed size, typically 12-14 inches wide for adult chest prints. Files should be sized to actual output dimensions, not scaled up from small web graphics.

What's a print area and how does it vary?

Print area is the maximum space available for decoration on each garment location. Standard adult chest prints fit within roughly 12×16 inches, but this shrinks for youth sizes, sleeve prints or pocket designs. Each printing method and press has physical limitations. Designs must fit within these boundaries with clearance from seams and edges.

Do designs need to be mirrored or positioned in a specific way?

Heat transfer methods like vinyl cutting require artwork mirrored horizontally before cutting, then flipped during application. Screen printing and direct-to-garment use artwork right-reading as designed. Placement guides showing centre lines and distance from collar help printers position artwork consistently, especially for all-over prints or specific design placements.