Custom Tshirts Manufacturing From 100 Units

Core Neckline Blocks

Crew necks use a close rib collar and remain the broadest unisex volume choice; V-necks create a more open neckline for womenswear, resort, and smart-casual assortments. Two neckline blocks can share a fabric and print program, but each needs its own collar measurement and fit approval. Keep crew necks as the core SKU and use V-necks as a targeted extension.

Relaxed And Fitted Shapes

Oversized tees add dropped shoulders, longer sleeves, and extra chest ease, making them suited to streetwear, music merchandise, and premium graphic drops. Fitted tees use closer chest and sleeve measurements for body-conscious or athletic customers. Grade each block separately; simply enlarging a fitted base can distort shoulder balance and body proportion.

Weight And Detail Variants

180–220 GSM jersey supports everyday retail tees, while 240–300 GSM heavyweight styles deliver a structured hand for elevated basics and streetwear. Pocket tees create a quieter logo location and work well for lifestyle, workwear, or resort capsules. Raglan sleeves add contrast-color merchandising and easier shoulder mobility for teamwear-inspired assortments.

Seasonal And Active Styles

Long-sleeve tees extend a graphic program into cooler seasons and layer under overshirts, jackets, or knitwear. Plan sleeve-print placement separately because it changes decoration cost and packing presentation. Performance tees typically use moisture-managing polyester or blends for gyms, events, and team channels. Confirm stretch recovery, opacity, and decoration compatibility before selecting heat transfer, sublimation, or screen printing.

Natural Fiber Choices

180–260 GSM combed ringspun cotton has a smoother, softer hand than open-end cotton and supports sharp screen prints; choose it for premium streetwear and retail basics. 160–220 GSM organic cotton follows the same performance logic, but request applicable GOTS documentation for any certified claim. Cotton breathes well, while pre-shrinking or wash testing controls its typical first-wash movement.

Blends And Performance

50/50 CVC combines cotton comfort with polyester durability and faster drying, making it practical for value basics and promotional programs. Polyester resists wrinkles and holds color well, but can feel warmer and requires suitable low-migration inks. Tri-blends commonly combine cotton, polyester, and rayon for a lightweight, drapey vintage hand. Stretch jerseys with 3–8% elastane improve recovery for fitted styles, while recycled blends need composition-specific testing for pilling and print adhesion.

Match Fabric To Program

220–300 GSM single jersey or heavyweight interlock gives premium streetwear a structured silhouette; verify neck-rib recovery after laundering. 160–180 GSM ringspun jersey is the dependable retail-basic range. 140–180 GSM polyester or stretch performance knit suits activewear where wicking and abrasion matter. 140–160 GSM CVC is a cost-conscious choice for events, uniforms, and broad promotional distribution.

Print Method Selection

Screen printing excels on 100+ units when artwork uses spot colors; DTG suits photographic detail and small tests. DTF and heat transfer handle multicolor designs without screens, though hand feel is more noticeable. Discharge removes dye on suitable dark cotton, creating a soft vintage result; puff ink adds raised dimension. Confirm cure testing after washing, especially on garment-dyed blanks.

Texture And Placement

Embroidery delivers durable, dimensional logos but can pucker lightweight 160 GSM jersey. Appliqué creates a cut-and-sewn statement, while woven patches provide crisp small text and a separate branded texture. A 6–10 cm left-chest logo usually suits embroidery or a woven patch; large chest artwork generally suits print. Use backing and placement samples to check drape.

Branding Layers

A neck print removes a sewn label for a cleaner interior, while woven main, size, and wash-care labels support private-label retail presentation. Add labels after approving the actual neck-rib stretch and seam allowance. Garment dye can deepen a washed aesthetic before discharge or tonal embroidery; test color migration first. Acid wash, enzyme softening, and puff graphics need a full decorated wash sample.

Neck And Shoulder Stability

A 5–10% collar stretch-and-recovery check can reveal weak rib, poor neck binding, or waviness before wear testing. Request shoulder-to-shoulder tape, collar rib composition, rib width, and seam construction on the sample. A 1/4-inch needle gauge is common for neck and shoulder coverstitch work, but the tech pack should specify the actual machine and stitch type. Compare the approved sample after laundering, not only when new.

• Check collar recovery after 10 hand stretches
• Confirm shoulder tape reaches both neck seams
• Inspect neckline for twisting after one wash

Seams And Hem Finish

A 10–14 stitches-per-inch range is typical for stable T-shirt seams, subject to fabric weight and thread size. Low density can open under tension; excessive density can pucker lightweight jersey. A side seam should hang straight with matched stripe, panel, and hem alignment. Specify sleeve and bottom-hem width, twin-needle spacing, thread color, and acceptable roping in the tech pack.

• Pull-test underarm and side seams
• Measure sleeve-hem depth at four points
• Check twin-needle stitches for skipped loops

Fabric And Wash Performance

A 180 GSM jersey should remain near its specified weight across lots; require a tolerance and test method rather than accepting a nominal label. Ask whether the fabric is compacted or pre-shrunk and measure post-wash shrinkage by length and width. AATCC colorfastness testing is relevant for dark shades, garment dye, and contrast trims. Approve a washed color standard under agreed lighting before bulk production.

• Record GSM from approved fabric swatch
• Request wash shrinkage results by direction
• Approve Pantone and wash-tested shade

Measurement Control

A ±1 cm tolerance may suit many adult knit-body points, while collar opening and sleeve length often need tighter control. List point-of-measure diagrams, grading increments, and wash-state measurements in the tech pack. A pre-production sample should use the bulk-intended fabric, rib, thread, label placement, and decoration. Junsheen can retain approved patterns and graded size sets to support repeat-order consistency.

• Approve a full graded size set
• Measure before and after wash
• Sign off the pre-production sample

Match Service To Your Brief

OEM means the factory builds your approved tech pack; ODM adds design, fabric and specification development. Ask whether pattern creation, size grading from XS–3XL, and pre-production samples are handled in-house. 100 units per style and color is a practical test MOQ for many cut-and-sew programs. Confirm the MOQ after fabric, color, decoration, and packaging choices are locked.

• Who owns approved patterns and graded files?
• What changes after sample approval?
• Can the same specification be repeated?
• Which options increase the MOQ?

Audit Production Controls

3 checkpoints—incoming fabric, in-line sewing, and final packed goods—should be traceable to an inspection standard. Request measurement tolerances, defect-handling rules, decoration wash-test evidence, and photos of bulk approvals. OEKO-TEX, GOTS, WRAP, and BSCI documents address different material or social-compliance scopes. Ask for current certificates applicable to the supplied mill or factory rather than accepting a generic logo.

• Fabric composition and weight records
• Pantone and strike-off approvals
• Measurement and AQL inspection reports
• Current compliance documentation

Test Communication And Scale

7–14 days is a common target for an initial development sample after materials are confirmed, while bulk lead time depends on fabric availability and order complexity. Require a dated critical path covering sourcing, sample approval, production, inspection, and export booking. 2 repeat-order questions reveal operational maturity: Can the factory reserve or reorder the approved fabric? Can it retain patterns, graded size sets, trim specifications, and QC records for the next production run?

• Who provides one accountable production contact?
• How are delays escalated and documented?
• Which export documents are supplied?
• What capacity is available in peak season?

Lowest Quote Trap

Three quotes can differ because fabric weight, print coverage, trims, packing, and defect allowance differ. A low quote can create reorders or chargebacks; compare like-for-like specifications and obtain a written cost breakdown.

Artwork And Fabric Mismatches

One Pantone file is not a production approval: screen prints should be tested on the approved fabric, color, and finish. Skipping strike-offs risks poor opacity, dye migration, cracking, or distorted detail; approve a physical print test and wash test before release. 160 GSM lightweight jersey and high-density silicone prints are often a poor pairing because the fabric may torque or show through. Match decoration to fabric weight, stretch, and surface, then record ink, mesh, placement, and curing requirements.

Fit, Shrinkage, And Tolerances

3–5% shrinkage after washing can make a graded size run fail its intended measurements. Ignoring shrinkage and grading causes inconsistent fit and returns; approve a wash-tested size set from XS through 3XL where applicable. 1–2 cm measurement differences may be acceptable at some points but unacceptable at a collar or chest. Define point-of-measure tolerances, wash method, and acceptable defect standard in the tech pack and PO.

Labels And Final Inspection

1 missing fiber-content, care, country-of-origin, or size label can block sale in the destination market. Confirm market-specific labeling, label placement, barcode data, and packaging artwork before bulk booking. 100% of packed cartons should not be assumed correct after factory completion. Skipping pre-shipment inspection can leave measurement, decoration, assortment, and carton-count errors undiscovered; schedule final AQL-based inspection before balance payment and shipment.

Define The Capsule

3–5 SKUs are enough for a first drop: for example, a core tee, heavyweight tee, oversized tee, long-sleeve tee, and one layering piece. 2–3 colorways per style keep fabric buying, photography, and fulfillment manageable while creating recognizable brand continuity.

Prepare Production Files

1 tech pack per style should specify flat sketches, measurements, grading, fabric GSM, Pantone colors, artwork size and placement, labels, and packaging. 1 reference garment or clear mood board helps translate intended fit and finishing where drawings alone are incomplete.

Sample Before Selling

1 development sample should verify body balance, neck shape, shrinkage, print registration, and hand feel before bulk approval. 2 revision rounds are common; approve a signed pre-production sample only after measurements, color, decoration, and branded trims match the specification.

Validate Demand At 100 Units

100 units per style and color can support a controlled launch without committing to a large inventory position. Allocate units across priority sizes using expected customer data, not equal-size splits. 1 consistent unboxing system—main label, care label, hang tag, polybag or mailer, and barcode—makes a small capsule feel intentional at retail.