Customization: Screen Printing
Things to consider for cost-effective Screen Printing:
DESIGN | QUANTITY | FABRIC | ||||||
|---|---|---|---|---|---|---|---|---|
 | |  |  |  | | | | |
UP TO 6 COLORS IN SINGLE PRINT SETUP: NO MINIMUM ORDER
7-12 COLORS IN SINGLE PRINT SETUP: 144+ Piece Minimum
(see below RECOMMENDED MINIMUMS PER TOTAL COMBINED COLOR SETUPS)
- REQUIREMENTS
- How Much?
ABOUT SCREEN PRINTING
Screen printing – in our use and application – is a print method that applies very thick ink to blank t-shirts (or other garments/apparel/etc). This process takes a LOT of set up time. However, once the printing has begun… you’ll need a few extra pairs of hands to keep up with the stacks piling high! You’ll need GREAT artwork and layouts before any of this process can begin, and we’ll assume you’ve already approved your graphics with the Creative Team in order to begin production.
SCREENS
As in the diagram, the logo is blocked out with a liquid film that dries on the screen – which is very much like a stencil. Then, we’ll print out the image In our shop, we actually burn the liquid to dry, and it leaves open your ‘stencil’ for the shirt to receive the ink. Each color that will end up on your shirt will need its very own screen. So, if you’ve got 6 colors going on your front logo and 4 colors going on your back – we’ll be prepping 10 screens with your designs.
LINING UP THE ARTWORK
Once the screens have completed the setup process, it’s over to our automatic screen printing presses and manual screen printing presses. We even have screen printed numbers and other items! Each color must be aligned so your image comes out sharp, crisp and on point… so you can guess, this is sometimes a long (but fruitful) endeavor.
THE LOOK & THE BENEFITS
Aside from the cost benefits, screen printing offers an exceptionally valuable perk – VIVID & POPPING COLOR! The colors you see coming out of a desktop printer or even our own Direct To Garment Printer will never be as full and saturated “Spot Color” inks from our huge selection. Another perk? Since the inks go on wet and then heat up, we are able to monitor the temperatures to ensure the “curing” has reached optimal levels on every single piece that leaves our shop! This means that you’ll enjoy our shirts MANY more wears and tears in the future!
Customization: Direct Embroidery
DESIGN | QUANTITY | FABRIC | ||||||
|---|---|---|---|---|---|---|---|---|
| | | | | | | | |
NO MINIMUM ORDER
Up to 12 thread colors in single design
- REQUIREMENTS
- How Much?
ABOUT EMBROIDERY
Embroidery is an application of threads, patches or combination of cut fabrics using needles. On our automated machines, we often run 6 or 8 items with the SAME DESIGN at the SAME time. This method of embellishment for your apparel and other promotional products always looks sharp and professional. You’ll need GREAT artwork and layouts before any of this process can begin, and we’ll assume you’ve already approved your graphics with the Creative Team in order to begin production.
DIGITIZING
As in the workflow, in order to embroider a design, the artwork must first be “digitized”. Our Creative Department technician (also called a “digitizer”) creates a sequence of stitches as a program for the embroidery machines. Every thread in the artwork has its own place in the digitized arrangement. The digitized file is “sewn out” to assure that the design will retain the highest standards of quality.
DESIGN SIZING + FABRICS
Sizing for embroidery is a common point of discussion with all of the variables at hand. The keys to great embroidery are knowing when you’ve got to make concessions to accommodate for the size of threads, and how they will be optimally arranged so that designs and fonts are legible. A very common problem is with the small text: Often, logo taglines will need to be removed or made much larger due to limitations of threads.
Fabric considerations are often about 2 main points: the comfort of the worn garment and the rigidity of the fabric to hold the stitching together without skewing or warping the design. Comfort is an issue primarily when the back of the stitches are in a place that has immediate or close contact with the skin – very irritating! In addition to this, we don’t want to pull our shirt out of the dryer and see a shrunken chunk on our shirt where our logo once was. To avoid these issues, we suggest working with midweight fabrics that are worn with undergarments that have a rigid texture to hold your sewing.
THE LOOK & THE BENEFITS
Embroidery has many applications- the common denominator is a clean and professional presentation. We know this is the power-apparel that can make or break a first impression. This is why our team makes sure YOUR team looks its best.
Customization: Direct to Garment (DTG)
Things to consider for Direct to Garment Prints:
DESIGN | QUANTITY | FABRIC | ||||||
|---|---|---|---|---|---|---|---|---|
| | | | | | | | |
NO MINIMUM ORDER
Up to 72 pieces recommended maximum print runs
- SAMPLES
- REQUIREMENTS
- How Much?
ABOUT DIRECT TO GARMENT (DTG) PRINTING
For the past 10 years, the custom t-shirt industry has been able to rapidly grow with “on-demand” methods that do not require long and painful setup times or materials (and since time is money – a LOT has been saved). One of the greatest machines for print-on-demand (POD) is the DTG – a single piece, full-color digital print solution that can be utilized on light or dark garments. You’ll need GREAT artwork and layouts before any of this process can begin, and we’ll assume you’ve already approved your graphics with the Creative Team in order to begin production.
LIMITATIONS
Like many things that cut through industry barriers, there are limitations to taking advantage of the on-demand full-color printing. The primary variables in considering DTG reduce to 3 components: 1. The fabric of the garment; 2. The use or need for white ink (printing on darks); 3. The overall quantity of the print run.
- Fabrics: 100% cotton is the fail-proof fabric for DTG prints. Any potential blends of polyester or other materials will cause severe fading, otherwise known as “bleeding”. When considering the DTG, you will need to be flexible with your fabric needs.
- White Ink: It may seem silly, but most digital print methods actually never utilize white inks. If you think about why – imagine the color of your standard copy paper… chances are it is white, or bright enough to still have a legible print result. This is the exact limitation of DTG that brings us to the ‘white ink dilemma’: While it is a 100% viable and proven option, white ink carries a heavy price tag. If you require a vivid, high contrast, creative and professional graphic design on your dark apparel – white ink will be required to do the job. For this reason, you will want to ensure that the desired appearance of your t-shirt calls for this premium consideration.
- Quantity: As mentioned above, ‘print-on-demand’ is a great application when you want full-color prints ordered at low quantities. A (1) shirt job that would have cost $240 in Screen Print Setup fees plus $28 for the single t-shirt will have a DTG price tag of merely $22 (more on pricing in the next section). However, it has been proven that there is little to be gained from the high cost of running these prints in bulk because you will save a great deal by running the design(s) as a screen print. Our rule of thumb for the maximum quantity of a bulk DTG print run is no more than about 72 prints. After that? Switch to screen print!
THE LOOK & THE BENEFITS
By now, it’s quite obvious the benefits of full-color printing and prints on-demand/single piece orders. We love to set up our DTG with fun and creative layouts – just another benefit to not having any color restrictions. Send us the craziest and most colorful art you can come up with! Or, better still, challenge our Creative Department with the task!
