Custom Screen Printed Tshirts From 100 Units

Core Crewneck And Heavyweight

150–180 GSM classic crewnecks suit broad unisex programs, event merchandise, and accessible logo tees; their regular silhouette accepts chest, back, and full-front screen prints cleanly. 240–300 GSM heavyweight or oversized tees target streetwear customers seeking structure and drop shoulders. Use bold large-format graphics and limited-color drops, then merchandise them as premium hero pieces.

Fitted And Pocket Tees

140–170 GSM fitted fashion tees suit contemporary labels and customers wanting closer sleeves, shorter bodies, or shaped side seams. Small chest prints, tonal inks, and restrained branding preserve the garment’s fashion-led role. 160–200 GSM pocket tees add a functional visual break for casual and workwear assortments. Print above, beside, or on the pocket carefully; pocket placement can complicate large front artwork and should be sampled first.

Long-Sleeve And Performance Blends

160–220 GSM long-sleeve tees extend a graphic program into transitional weather and skate, workwear, or layered collections. Front graphics paired with sleeve prints create higher perceived value without changing the core silhouette. 130–180 GSM performance or cotton-poly blended tees serve activewear, staff uniforms, and warm-climate promotions. Choose low-bleed inks and test print adhesion on polyester-rich fabric; prioritize moisture management and repeat-logo utility over dense hand feel.

Fiber And Yarn Choices

Ring-spun cotton uses finer, smoother yarn than open-end cotton, giving a softer hand and cleaner ink edge. Organic cotton follows the same performance logic, but certification scope should be verified per fabric lot. Recycled cotton is commonly blended with virgin cotton or polyester because recycled fibers shorten during processing. Polyester resists shrinkage and wears hard, while cotton-poly blends balance opacity, softness, dimensional stability, and cost.

• Open-end cotton: value-focused, drier hand
• Ring-spun cotton: premium retail softness
• Polyester: performance and sublimation bases
• Cotton-poly: dependable everyday programs

GSM And Knit Structure

150–180 GSM single jersey suits lightweight promotional or warm-climate tees; 180–220 GSM supports mainstream retail; 220–260 GSM creates a substantial oversized hand. Combed ring-spun yarn and tighter jersey reduce surface hairiness, improving fine-detail prints. Rib is best reserved for collars, while interlock offers a denser, smoother face with more opacity. Fleece and French terry belong to heavier garments, not standard screen-print tee bases.

Shrinkage, Dye, And Ink

3–5% shrinkage is a practical wash-test allowance for untreated cotton, whereas polyester and stable blends usually move less. Request compaction or pre-shrinking when final measurements are tight. Reactive-dyed cotton typically gives rich color and strong print absorption; polyester needs disperse dye and can show dye migration under heat. Dark bases need an underbase for bright plastisol colors, while water-based ink feels softer but depends on absorbency and curing control.

Prepare Artwork And Separations

1-color spot art uses one screen per ink and delivers the most controlled solid color. Simulated-process separations build photographic detail from halftones and several spot inks, so test prints are essential. 12-inch chest art and 3-inch left-chest marks require different screen sizes, registration tolerances, and curing checks. State garment color, print width, placement from HPS, and whether artwork may overlap seams.

• Provide vector AI, EPS, or PDF logos
• Use 300-DPI raster art at print size
• Name Pantone colors and underbase requirements

Select Ink For The Garment

Plastisol gives opaque, durable color on cotton, blends, and dark garments, but leaves a heavier film. Water-based ink has a softer hand on absorbent cotton; discharge removes dye before adding color and needs dischargeable, high-cotton fabric. Puff, metallic, foil, silicone, high-density, and flock are specialty effects requiring compatible artwork, controlled deposits, and wash testing. Confirm cure temperature against heat-sensitive performance blends.

Finish The Brand Experience

2 placements usually cost more than one because each location needs its own setup, loading step, and quality check. Higher color counts add screens and registration time, so simplify secondary marks where possible. 1 neck print can replace a woven main label; add size and care information where required. Hangtags, folded bags, custom mailers, garment dye, enzyme wash, acid wash, or softening should be approved on the production sample.

• Confirm neck-label legal content by market
• Approve packaging dimensions and barcode position
• Wash-test specialty prints before bulk approval

Collar And Shoulder Stability

A 1×1 rib collar should recover after a firm stretch without waving; verify rib weight, neck opening, and coverstitch consistency on approved samples. A shoulder-to-shoulder neck tape stabilizes the neckline and hides the seam. Check that both shoulder seams sit evenly and that tape does not pucker the jersey.

• Stretch-test collar recovery after wash
• Check neck tape ends and seam bulk
• Compare left and right shoulder lengths

Seams And Hem Finishing

A 10–12 stitches-per-inch lockstitch is a practical benchmark for clean jersey seams, while loose stitches can open under wear. Confirm side-seam alignment or specify a tubular body when avoiding side seams matters to the design. A twin-needle sleeve and bottom hem should remain flat after washing. Inspect hem width, skipped stitches, twisting, and whether the print sits square to the body grain.

• Measure sleeve and bottom hem widths
• Check side-seam twist after laundering
• Inspect skipped stitches under tension

Shrinkage And Measurement Control

A 3–5% wash-shrinkage allowance is common for cotton jersey, but the approved specification must state the method and target measurements. Pre-shrinking or compaction should be confirmed before bulk cutting. A ±1 cm chest and body-length tolerance is often workable for standard tees; critical fit points may need tighter limits. Retain the sealed size set, graded pattern, and measurement chart for repeat orders.

• Record before-and-after wash measurements
• Measure chest, length, shoulder, and sleeve
• Approve grading across XS through 3XL

Wash Test Before Bulk

One production-representative wash test should assess shrinkage, spirality, collar recovery, seam puckering, and print position. Use the intended care cycle rather than a gentle sample wash. Two or more washed garments provide a better check against one-off variation. Photograph measurements and defects against the approved sample so future reorders use the same acceptance standard.

• Verify print remains centered after wash
• Check color transfer and surface pilling
• Archive results with material records

Match The Production Model

100-unit style-and-color programs suit a capsule launch, but confirm whether the MOQ applies per color, per print placement, or across a combined order. A supplier experienced in fashion tees should discuss 180–260 GSM jersey, collar recovery, shrinkage, and graded sizing—not only ink colors. 2 capability checks separate full-package production from decoration-only service: ask who owns the pattern, sources Pantone-matched fabric, and retains approved specifications for repeats.

• Can they develop blanks from a tech pack?
• Can they support XS through 3XL grading?
• Can they quote landed export terms clearly?

Approve Artwork And Samples

1 pre-production sample should show the actual fabric, print method, placement, and colorway whenever possible. Require artwork review for line weight, halftones, underbase needs, trapping, and print-area limits before screens are made. 3 approval questions prevent expensive ambiguity: Is the Pantone target achievable on this garment color? What wash test verifies cracking, adhesion, and color loss? Which signed sample and measurement tolerance govern bulk production?

Verify Controls And Communication

200-worker factories with documented in-line and final inspection can support larger replenishment programs, but buyers should request the current production calendar rather than rely on generic lead-time promises. Confirm capacity, sample timing, bulk timing, inspection points, and shipping handoff in writing. 4 compliance questions are practical: Which documents can be provided for the fabric, inks, factory, and social audits? Are OEKO-TEX, GOTS, WRAP, or BSCI records applicable to this order? Who answers defects, customs paperwork, and export booking?

• Ask for a print-QA checklist.
• Confirm final balance timing before shipment.
• Name one accountable sales and production contact.

Prepare Production-Ready Artwork

300 DPI artwork at final print size prevents jagged edges, trapped details, and expensive redraws. Send vector AI, EPS, or PDF files with separated spot colors and defined print dimensions. 0.5 mm lines and tiny knockouts can fill during printing, particularly after wash. Ask the supplier to flag minimum line weight, halftone limits, and required color separations before quoting.

Specify Ink And Garment Colors

1 dark garment usually needs a white underbase beneath bright plastisol or water-based inks. Omitting it produces dull color, weak opacity, and a sample that cannot match the approved artwork. Pantone codes—not names such as navy or cream—give the production team a reference. Approve an ink drawdown or strike-off under the intended lighting before bulk.

Test Fabric, Fit, And Wash

160–220 GSM cotton jersey and blends accept ink differently, especially with silicone softeners, dye migration, or high polyester content. Test the actual bulk fabric with the proposed ink system before locking the fabric order. XS–3XL measurements, tolerances, and post-wash shrinkage must be written into the tech pack. Run wash tests and a full size set; rushed sample approval leads to rework, returns, and inconsistent repeat orders.

Quote Total Production Cost

4 spot colors usually require more screens, setup, registration time, and unit cost than a 1–2 color graphic. Request a color-count breakdown, including underbase, flash cures, print locations, and screen charges. 100-unit MOQ pricing can hide freight, rejects, relabeling, and inspection gaps when suppliers compete only on unit price. Compare sample quality, documented QC, lead time, communication, and total landed cost before awarding production.

Build The Assortment

3 to 5 coordinated graphics create a clearer launch than unrelated one-off prints. Set hero, secondary, and repeatable logo treatments using shared type, Pantone colors, and placement rules. 2 core blanks and 2 colorways usually keep early inventory manageable. Plan size ratios from expected customers, then reserve proven colors and graphics for replenishment.

• Define target customer and retail price
• Assign hero, support, and logo graphics
• Set size curves before purchasing blanks

Prepare Production Files

1 complete tech pack should specify measurements, fabric GSM, neck rib, stitching, labels, packing, and graded size chart. Supply vector artwork, Pantone references, print dimensions, placement points, and separated colors. 6-color artwork needs a screen-by-screen separation review before sampling. Confirm halftones, underbase requirements, ink type, and allowable registration tolerance with the factory.

• AI, PDF, or EPS vector artwork
• Named spot colors and print locations
• Front, back, sleeve, and neck details

Approve Before Bulk

1 prototype verifies hand feel, fit, shrinkage, and graphic scale before production. Compare like-for-like quotes: fabric composition, GSM, print colors, label package, MOQ, sampling charges, and freight terms. 1 signed pre-production sample should lock fabric, print, measurements, trims, and packaging. Schedule in-line checks, final AQL inspection, balance payment, and shipping around the launch date.

• Measure approved size points
• Wash-test print and shrinkage
• Photograph approved sample for ecommerce

Plan The Release

4 to 6 weeks of content preparation helps retailers launch with consistent product pages. Photograph front, back, detail, fit, and movement views; retain the approved sample as the visual reference. 30 to 60 days of sales data can guide replenishment decisions. Keep artwork files, graded patterns, material records, and color standards organized so repeat orders stay consistent.

• Create SKU and barcode plan
• Book freight before final inspection
• Set replenishment trigger levels