The Secret Behind T-Shirt Manufacturers' Preferred Printing Methods

T-shirts are a versatile garment with mass appeal, available in a variety of colours, patterns, and styles. The majority are made from 100% cotton, polyester, or a blend of the two. Manufacturers may also use knit fabrics, such as jerseys, rib knits, and interlock rib knits, to create stretchable T-shirts.

T-shirt manufacturers use various techniques to apply designs to garments, including embroidery, screen printing, transfer printing, and direct-to-garment (DTG) printing. Each method has its advantages and suitability for different fabrics and design types.

Embroidery creates a premium look and feel by stitching the design directly onto the T-shirt, often used for logos, monograms, or text. Screen printing uses a mesh screen to apply ink and produce vibrant colours and sharp edges, ideal for bulk orders. Transfer printing uses heat to apply a design printed on transfer paper, suitable for smaller quantities and designs with many colours or gradients. DTG printing uses a specialised inkjet printer for highly detailed designs and is best for smaller orders due to its higher cost.

Fabric and material types

T-shirts are usually made from 100% cotton, polyester, or a blend of the two. Stretchable T-shirts are made from knit fabrics, especially jerseys, which are comfortable, versatile, and relatively inexpensive. They are also a good material for screen prints and heat transfers. Rib knits are used when a snugger fit is desired, and interlock rib knits are used for higher-quality T-shirts.

Luxury T-shirts are made from premium cotton, silk, linen, or other high-quality fabrics. Promotional T-shirts, on the other hand, are often made from cheaper materials and are designed for short-term use as branding tools.

Some manufacturers offer customisation options, allowing clients to choose the fabric of their T-shirts. For example, Steve Apparel offers custom screen printing and private label clothing options, while Apparel Empire offers customisation of all aspects of the apparel, including fabric, and uses UPF resistance technology to make their T-shirts waterproof and fireproof.

Printing and embroidery techniques

Direct-to-Garment (DTG) Printing

Direct-to-garment printing, as the name suggests, involves applying ink directly onto the T-shirt fabric. This method uses an inkjet printer to produce high-quality, full-colour prints that are ideal for complex designs or photographic images. DTG is perfect for small batches as it has no setup costs, and the ink seamlessly integrates into the fabric, leaving no texture. It is best suited for 100% cotton T-shirts or cotton blends. However, DTG prints tend to wash out over time and are more expensive for larger orders due to the setup costs involved.

Screen Printing

Screen printing, also known as silkscreen printing, is one of the most popular printing methods for T-shirts. It involves applying ink indirectly through a mesh screen stencil, printing one colour at a time. This method is effective for producing vibrant and durable designs on various fabrics, including polyester and cotton blends. Screen printing uses thicker inks that result in long-lasting prints. It is more cost-effective for large quantities (up to 500 T-shirts) and can withstand countless wash cycles. However, it has a limited printing area and is not suitable for extremely colourful or vivid designs.

Heat Transfer Printing

Heat transfer printing is another popular method that uses a heat press to transfer an image or design onto the T-shirt. This technique does not require special inks or dyes, only a heat press machine and transfer paper. It allows for almost any design to be printed, including all-over prints that cover the entire shirt. Heat transfer printing has several subtypes, including dye sublimation and direct-to-film (DTF) printing.

Dye Sublimation Printing

Dye sublimation, also known as all-over printing (AOP), is a unique process that uses heat to transform dye-based ink into a gas, bonding it with synthetic materials like polyester. This method embeds the ink deeply into the fabric, resulting in vibrant and durable prints. It cannot be used with cotton due to bleeding issues and is more expensive than other printing techniques.

Direct-to-Film (DTF) Printing

Direct-to-film printing involves transferring designs from a special PET film to T-shirts using adhesive powder and heat. DTF works on various fabrics and offers bright and vibrant results. It leaves a shiny, plasticky finish due to the fixing powder. This method is highly resistant to wear and tear but is more complex and expensive than other techniques.

Heat Transfer Vinyl (HTV) Printing

Heat transfer vinyl printing, also known as iron-on printing, uses vinyl plastic-based sheets. The design is cut out manually or with a machine, coated with an adhesive, and applied to the T-shirt using an iron or heat press. HTV creates stiff designs and is limited to fabrics that can withstand the heating process. It is not suitable for dark backgrounds or large-scale production.

Plastisol Transfer Printing

Plastisol transfer printing is an indirect screen printing technique that uses a plastic-based transfer sheet. It is similar to screen printing but applies ink to heat transfer paper instead of directly to the T-shirt. Plastisol printing produces durable prints that resist fading and cracking. However, it cannot be used for photographic images or large orders.

Embroidery

Embroidery is a sophisticated and durable technique that uses a sewing machine to create designs on T-shirts. It results in a professional and timeless look but has strict design requirements, limited colour variations, and a smaller product range. Embroidery is more expensive than other printing methods but is incredibly long-lasting.

Airbrushing

Airbrushing is a manual printing technique that uses a small spray painting tool to apply paint to the fabric. It allows for artistic freedom and custom, one-of-a-kind designs. However, airbrushed designs lack durability and intricate detail, making them unsuitable for large orders.

The choice of printing or embroidery technique depends on various factors, including design complexity, fabric type, order volume, and budget. Each method has its advantages and disadvantages, and selecting the right one ensures the desired quality and style for the T-shirts.

Design and customisation

T-shirt manufacturers offer a range of customisation options to their clients, depending on their requirements. The design and customisation process for t-shirts can be summarised in the following steps:

Design and Concept

The process typically begins with designers creating unique and innovative designs that align with the client's brand image, target audience, and specific requirements. This involves brainstorming ideas, considering the target market, and determining the desired style, colours, and graphics or text to be included on the t-shirts.

Material Selection

The choice of material depends on the desired quality and purpose of the t-shirts. High-end designer t-shirts often use premium materials such as cotton, silk, linen, or other luxurious fabrics, while promotional t-shirts may use more cost-effective options.

Fabric Sourcing

Manufacturers source the required fabrics based on the chosen materials. They may work with specialised fabric suppliers to obtain exclusive, limited-quantity fabrics for luxury t-shirts. Sustainable and ethically sourced materials are also becoming increasingly important to consumers.

Pattern Making and Cutting

Pattern makers create precise patterns based on the designer's sketches and specifications, ensuring a perfect fit and consistency across different sizes. The patterns are then used as a guide to cut the fabric into individual pieces for each t-shirt, requiring attention to detail to maintain quality.

Sewing and Assembly

Skilled artisans or highly trained sewing machine operators assemble the cut fabric pieces together. The sewing process may involve meticulous stitching and the use of high-quality thread to ensure durability, especially for luxury garments.

Finishing and Embellishments

Before the final quality control checks, t-shirts may undergo additional processes such as embroidery, hand-sewn details, or special prints to enhance their uniqueness and value.

Printing

Various printing techniques can be used to apply designs or logos onto the t-shirts, including embroidery, screen printing, transfer printing, and direct-to-garment (DTG) printing. The chosen printing method depends on factors such as the type of design, fabric, and quantity of t-shirts being produced.

Labelling and Packaging

The final step involves attaching branded labels and tags to the t-shirts, as well as packaging them in a way that reflects the brand's image and exclusivity.

Sourcing and supply chain

The next step is pattern-making, where precise patterns are created based on the designer's specifications, ensuring consistency in sizing. This is followed by the cutting process, where attention to detail is crucial to maintain quality. The cut fabric pieces are then assembled through sewing and stitching, often involving skilled artisans or highly trained operators.

Luxury T-shirt manufacturers may employ more intricate stitching techniques and high-quality thread to ensure durability. Finishing and quality control are then performed to meet the brand's standards, followed by any embellishments like embroidery or special prints.

Labelling and packaging are the next steps, where branded elements and special packaging reflect the brand's image. Finally, distribution occurs through boutiques, department stores, or online channels, completing the journey from design to the consumer's hands.

Packaging and distribution

Packaging:

The packaging process for T-shirts depends on the type of shirt and the intended distribution outlet. For T-shirts intended as underwear, the standard practice is to fold them neatly and package them in pre-printed clear plastic bags, which include information about the product. This type of packaging not only protects the garments but also allows customers to easily view the product.

For a more premium presentation, some T-shirt manufacturers also offer "boarding," where the T-shirts are folded around a piece of cardboard to maintain their shape during shipping and display. This method is particularly useful for high-end designer or luxury T-shirts, ensuring they arrive in pristine condition and are ready for display once received by retailers.

Distribution:

The distribution channels for T-shirts vary depending on the nature of the business and the target market. For instance, luxury designer T-shirts are typically sold through high-end boutiques, exclusive department stores, or directly from the brand's flagship stores and official websites. This distribution strategy aligns with the exclusive nature of these products and helps maintain their premium image.

On the other hand, wholesale T-shirt manufacturers often distribute their products in bulk to various retailers, including local boutiques, gift stores, T-shirt shops, and larger retail chain stores. This distribution model allows for higher sales volumes and accessibility to a wider range of consumers.

Additionally, with the rise of e-commerce, many T-shirt businesses, especially startups and smaller brands, opt to sell their products directly to consumers through their own websites or popular e-commerce platforms like Shopify. This direct-to-consumer model eliminates the middleman and can offer cost savings for both the business and the customer.

In summary, the packaging and distribution processes for T-shirts are tailored to the specific needs and target markets of the manufacturer. By selecting appropriate packaging methods and distribution channels, T-shirt businesses can effectively deliver their products to the intended consumers, contributing to a successful and efficient operation.

Frequently asked questions