The 7 Biggest Custom T-Shirt Ordering Mistakes (And How to Avoid Them)

Introduction: Don’t Let Your Custom Shirts Flop

Did you know? Nearly half of Americans (47%) would keep and wear a promotional t-shirt for two years or longer, and each shirt can generate over 5,000 impressions in its lifetime. Custom t-shirts can be an amazing tool for your business or team – if they’re done right. But if the shirt is low-quality or poorly designed, it might never see the light of day. As one startup expert put it, a bargain-basement $3 shirt is “mostly worthless” for promoting your brand, while spending a bit more on a nicer $7 shirt can be “priceless”. In other words, a well-made custom t-shirt can become someone’s favorite tee (free advertising for you!), whereas a bad one ends up in the trash – wasting your money and missing the opportunity.

Ordering custom shirts is easier than ever, but first-time buyers and even seasoned business owners often run into pitfalls that turn their dream shirts into duds. Avoid that fate! In this post, we’ll walk through the 7 biggest mistakes people make when ordering custom t-shirts – and, more importantly, how you can avoid them. From planning your project and choosing materials to finalizing your design and placing the order, we’ve got you covered. Let’s make sure your next custom t shirt order is a smashing success that everyone will love to wear.

Mistake #1: Skipping the Homework (No Clear Goals or Research)

The first mistake happens before you even design the shirt: not doing your homework. Many people jump into a custom t-shirt order without clearly defining what they want or who it’s for. As one print shop observed, a lot of newcomers struggle by “simply not knowing what you want from your merch, or who your audience really is” . If you don’t know your target, it’s easy to miss the mark. Common errors include choosing the first vendor you find, not reading reviews or comparing prices, and failing to think through the shirt’s purpose.

Why this is a problem: Without clear goals, you might end up with shirts that don’t fit your needs – maybe the design doesn’t resonate with your audience, or you paid too much by not shopping around. Not researching vendors can lead you to unreliable printers or hidden costs. For example, some companies may advertise cheap base prices but then upcharge for extras like certain ink colors, rush production, or shipping. If you haven’t done your research, your budget can spiral out of control, or worse, you get stuck with a printer who delivers subpar work.

How to avoid it:

• Define the “why” and “who”: Are these custom t-shirts for branding at an event, for your employees, or to sell to fans? Knowing the primary purpose will guide your decisions. Write down your goals (e.g. “Give our team a unified, professional look at the trade show” or “Create a band merch shirt fans will buy”) and keep your target audience in mind.

• Research and compare vendors: Don’t just go with the first Google result. Get quotes from multiple custom t-shirt companies before you finalize your order. Compare not only the price per shirt but what that includes: print quality, shirt brand, shipping, etc. A little research can reveal big differences.

• Check reviews and portfolios: Look at customer testimonials or ask for examples of previous work. A trustworthy custom shirt supplier should be happy to share their past projects. Make sure they have experience with the type of order you need (large bulk order, rush jobs, detailed prints, etc.).

• Ask about deals and deadlines: If you’re ordering in bulk, ask about bulk discounts or price breaks – sometimes ordering a few more shirts can actually lower your cost per piece. Also inquire about turnaround times and any rush fees (more on timing later). Being informed will help you pick a vendor that fits your needs and timeline.

Doing a bit of homework upfront will save you headaches and money. With clear goals and a vetted printer, you’re far less likely to hit snags down the road.

Mistake #2: Choosing Price Over Quality (The Cheapest Shirt Wins… and Fails)

If you’ve ever been tempted by those $3.99 custom shirt deals, this part is for you. It’s natural to want to save money, but skimping on quality is the fastest way to ruin your custom t-shirt project. Ordering the cheapest shirts you can find often means poor fabric, low-quality prints, and unhappy wearers. You might save a few bucks upfront, but you’ll pay the price later when the shirts rip, fade, or get tossed in the back of a drawer.

Signs of a “cheap” shirt: Crooked prints, peeling logos, designs that crack or fade after one wash, thin material that feels scratchy – you name it. A bargain shirt might look okay straight out of the box, but it won’t hold up. Remember, your custom t-shirt represents your brand or team. If it feels like sandpaper or falls apart quickly, it reflects poorly on you. As one entrepreneur noted, “Many of the startup t-shirts I see are completely worthless — no one is going to wear them who doesn’t get paid to”, because they’re ugly or uncomfortable. The last thing you want is to hand out shirts that people only wear to paint the house or not at all!

How to avoid it:

• Choose quality fabrics: Not all t-shirts are created equal. Look for reputable brands or ask your printer for recommendations. For instance, shirts made from ringspun cotton or tri-blends (e.g. a mix of cotton, polyester, and rayon) are super soft and tend to be favorites that people actually wear. A higher-quality tee might cost a couple dollars more, but it’s worth it because people will keep it and wear it over and over .

• Feel before you seal the deal: If possible, request a sample shirt or fabric swatch before placing a big order. Getting to touch the material gives you a sense of its thickness and softness. You’ll quickly tell the difference between a shirt that’ll become someone’s go-to vs. one that’ll be avoided in the closet.

• Beware of deals that are too good: That doesn’t mean you should overspend, but use common sense. If one vendor is offering a price dramatically lower than others, ask why. Are they using a thinner, cheaper shirt blank? Are the prints one-color vinyl instead of quality screen prints? There’s a saying: “You get what you pay for.” In custom shirts, a rock-bottom price often comes with rock-bottom quality.

• Invest a little more for big returns: Think of your custom t-shirts as an investment in marketing or team spirit. A comfortable, high-quality shirt can turn into free advertising as people wear it proudly. In fact, a single good t-shirt can deliver “tens of thousands of impressions” for your brand when worn in public. Spending an extra dollar or two per shirt for better quality can multiply the shirt’s impact. On the flip side, a cheap-feeling shirt may never be worn at all – zero impressions, zero ROI.

In short, don’t sacrifice quality for cost. Find the sweet spot where you’re getting a good price and a shirt people will love to wear. It might mean ordering 100 instead of 90 to hit a bulk discount, or choosing a slightly more expensive fabric, but your future self (and your shirt recipients) will thank you.

Mistake #3: Picking the Wrong Printing Method or Decoration

Not all printing methods are created equal, yet many people order custom shirts without realizing there are different ways to print a design. Each method – screen printing, direct-to-garment (DTG), heat transfer, sublimation, embroidery, etc. – has its pros and cons. Choosing the wrong one for your needs can lead to disappointing results. It’s like using a butter knife to cut a steak: it might get the job done, but it’s far from ideal!

Common pitfalls: Perhaps you wanted a vibrant photograph on your shirt, but you chose a printing method that can’t capture detail well. Or you have a small order and chose screen printing (which has setup costs that make small batches pricey) when DTG would have been more cost-effective. Maybe you didn’t realize that sublimation only works on certain fabrics (it’s great for polyester but won’t work on cotton). These missteps result in shirts that either cost more than expected, don’t look how you envisioned, or don’t last as long as they should.

How to avoid it:

• Learn the basics of each method: You don’t need to become a printing expert, but a little knowledge goes a long way. For example:

  • Screen Printing: Best for bulk orders and simple designs with a few colors. Very durable prints, but not cost-effective for short runs or designs with many colors.

  • Direct-to-Garment (DTG): Like an inkjet printer for shirts – great for full-color, highly detailed designs and small batches. The print is slightly less vibrant on dark shirts and not as durable as screen printing over many washes.

  • Heat Transfer/Vinyl: Good for individual shirts or names/numbers (like sports jerseys). Can have a heavier feel; might crack or peel over time.

  • Dye Sublimation: Fantastic for all-over prints or polyester shirts – the ink becomes part of the fabric. But it only works on light-colored, high-polyester content shirts.

  • Embroidery: Not printing per se, but stitching. Provides a high-class look for logos on polos or hats, but not used for large intricate designs on T-shirts.

  • DTF: Direct to Film is one of the best all around methods for printing on shirts. It produces vibrant colors, is soft to the touch and holds up through many washes. 

   

• Match the method to your project: If you’re unsure, ask your vendor for guidance. A good custom apparel company will recommend the best technique once they know your design idea, quantity, budget, and shirt material. For instance, if you have 500 custom shirts to give away at an event with a simple one-color logo, screen printing is likely ideal. If you need 20 shirts with a detailed multicolor graphic, DTG might be better suited.

• Consider durability and feel: Think about how the design will hold up. Screen prints, especially with quality inks, tend to last through many washes without fading, and the print feels soft if using water-based inks. Vinyl transfers might start peeling after a dozen washes if not done well. Make sure to communicate your expectations (e.g. “these shirts will be worn and washed frequently; they need to last”).

• Don’t forget cost implications: Some methods have higher setup fees (screen printing screens, embroidery digitizing) but lower cost per shirt in bulk, while others have no setup but higher per-shirt cost. If you’re on a tight budget or a weird quantity (say 37 shirts), discuss this with your printer. They might suggest slight adjustments to quantity or method to save money. For example, doing 50 shirts via screen print might be cheaper than 40 via DTG due to price breaks – it all depends, so get their insight. At Kavy's Customs we have no setup fees, no digitizing fees and no minimum order quantities.

The key is not to choose blindly. By understanding printing methods or consulting someone who does, you’ll ensure your custom t-shirt comes out looking perfect and you aren’t hit with unexpected issues (like a logo that starts peeling off). The right method = a print that matches your vision.

Mistake #4: Using Low-Resolution or Poorly Prepared Artwork

Your t-shirt’s design is its heart and soul. Even a great fabric and the perfect print method can’t save a bad design file. One of the biggest mistakes is sending your printer a low-resolution image or an artwork file that isn’t print-ready. The result? Blurry, pixelated logos, off-center designs, or unexpected font substitutions – yikes. As a custom apparel expert bluntly put it, “No matter how skillfully you handle the printing process, the final product will appear poor when blurry or substandard artwork is used.”

What can go wrong: If you grab your company’s tiny web logo and stretch it for a t-shirt, it will likely print fuzzy or jagged. Or maybe you designed something in a program like Microsoft Word or Paint that isn’t meant for high-quality graphics. Sometimes colors get messed up (your bright red might print as dull maroon) because the file was in the wrong color format. Another common hiccup is missing fonts – you used a cool font on your computer, but the printer doesn’t have it, so when they open your file, it defaults to a boring font (and messes up the layout). These issues lead to unprofessional looking shirts that nobody is proud of.

How to avoid it:

• Use high-resolution or vector artwork: Aim for at least 300 DPI (dots/pixels per inch) at the actual print sizefor any raster images (like JPEG or PNG). Even better, use vector formats like AI, EPS, or SVG for logos and illustrations – vectors can scale to any size without losing quality. If you’re not sure, ask your designer or printer. A clear, crisp design file is step one to a clear, crisp print.

• Follow the printer’s file guidelines: Every printer may have specific preferences (color mode CMYK vs RGB, file types, etc.). Communicate with your printing company’s design team and ask what they need. They might provide a template or require a certain format. Taking a few minutes to prep the file correctly can prevent costly reprints.

• Outline or embed your fonts: If you send an Illustrator or PDF file, make sure to convert text to outlines, or include the font files. This way, you won’t get the dreaded “missing font” issue where your cool script font gets replaced by Arial!

• Keep it simple (when possible): Sometimes, less is more. Too many tiny details might not show up well on fabric. Thin lines can bleed or disappear. Bold, clean designs often translate best to fabric printing. If your design has a lot going on, consider printing a sample (see Mistake #7) or at least get a digital proof to ensure those details come out okay.

• Double-check your proof: Most printers will send a digital mockup or proof before printing. Don’t skip reviewing it! Look for any spelling mistakes, color issues, or layout problems. It’s your last chance to catch an artwork mistake before it’s permanent on 100 shirts. We’ll talk more about proofs in Mistake #7, but in short: examine that proof closely on a big screen.

Remember, garbage in, garbage out. If you provide a high-quality design file, you’re setting yourself up for success. Your custom shirts will have sharp lines, readable text, and colors that pop – not the dreaded blurry blob design.

Mistake #5: Ignoring Size Differences and Placement Guides

One size does not fit all – and that applies both to the shirts and the design printed on them. A common mistake is treating all shirts as if they’re the same, failing to account for different sizes, cuts, and placement needs. The result? Maybe your logo looks perfect on a Medium, but on a 3XL it’s comically small, or half the design gets lost under someone’s arm. Or perhaps you only ordered unisex shirts and the women on your team end up with boxy tents that don’t fit. Not planning for size and placement variation can lead to ill-fitting garments and awkward-looking prints.

What this looks like: Say you design a front graphic to be 10 inches wide. On a small or medium shirt, that covers a good portion of the chest – looks great. On a XXL, that same 10-inch print might look oddly tiny in the sea of fabric. Similarly, if you positioned a design element too high or low based on one shirt mockup, it might hit an uncomfortable spot on other sizes. We’ve heard horror stories of logos printed so high they’re almost on the collar on smaller sizes, or so low on larger ones that they hit the belly area wrong. Also, ordering the wrong mix of shirt sizes is a risk – if you don’t gather size info or use an informed estimate, you might run out of some sizes and have too many of others.

How to avoid it:

• Plan your size breakdown: If you’re outfitting a group (employees, team, event staff), get size requests if possible. If not, use industry averages to distribute sizes (for example, mediums and larges often are the most common). For bulk orders, one guide suggests an approximate distribution or at least having a few extra of common sizes rather than an exact count. It’s better to have one or two left over than to have someone who needs a Large stuck wearing an XXL because you ran out.

• Consider unisex vs. ladies’ cuts: A unisex (men’s) shirt can work for most, but if you have a lot of women recipients, you might consider ordering a women’s cut for better fit. At the very least, be aware that unisex sizes run larger for women. Some businesses opt for a mix of unisex and female-tailored shirts.

• Adjust artwork placement for extremes: Talk to your printer about how the design scaling works on different sizes. Many printers keep the design the same dimensions across all shirts for consistency. This is usually fine, but if you’re printing a very large range (say S through 4XL), you might request a slightly larger print on the 2XL+ shirts so it doesn’t look dwarfed, or at least check a proof of the largest size. Use placement guidelines and mockups – most printers can show you roughly how the print will look on various sizes. As one expert noted, a design that looks great on a small shirt can appear very different on a big shirt if not planned for. Reviewing a mockup on both a small and a large shirt can be eye-opening.

• Center and standardize placement: Ensure the design is positioned correctly (usually centered both vertically and horizontally on the chest, unless intentionally a pocket-area print, etc.). Printers have standard measurements (for example, many place the design ~3 inches below the collar for adult sizes). Verify these specs on your proof or order details, so you don’t get a “postage stamp” logo near the neck or a graphic too low. Following proven placement guidelines will save you from an awkward result.

In summary, think ahead about the people who will wear these shirts. Different bodies and shirt sizes mean you should double-check how your design and sizing choices will work out. A little planning ensures everyone gets a shirt that fits well and looks great, from the smallest to the tallest person in the group.

Mistake #6: Waiting Until the Last Minute (Underestimating Turnaround Time)

Time can be a deal-breaker. One of the most frequent mistakes is underestimating how long it takes to produce custom shirts or failing to pad your timeline for safety. Custom printing isn’t usually as instant as clicking “Buy Now” on an online store. If you order too late, you might be forced to pay rush fees, settle for fewer options, or worst of all, miss your event deadline and have boxes of useless shirts arriving the day after your conference – oops!

Why timing matters: Printing shops have schedules and often a standard turnaround (commonly around 1-2 weeks for many print shops, but it varies). If you need shirts in hand by a specific date, you need to account for proof approval time, printing, curing (for screen prints to dry), and shipping. A big mistake is assuming “Oh, they can print 100 shirts in one day no problem” – not considering that there might be other jobs in queue or that your chosen method takes longer. Peak seasons (like summer event season or before school starts) can extend lead times. We’ve seen people place an order a week before their event and end up biting nails hoping it arrives in time, or paying hefty rush charges to expedite printing and overnight shipping. Don’t let poor planning sabotage your custom t-shirt project!

How to avoid it:

• Start the process early: As soon as you know you’ll need custom shirts, start contacting printers. Even if you don’t order immediately, find out their typical turnaround time. For example, if a shop tells you it’s 10 business days from approval to ship, and you need the shirts in 3 weeks, you know you’re on a tight clock (especially counting shipping transit time). A good rule of thumb is to place your order at least 3-4 weeks before you need the shirts. More time is better!

• Ask about rush options (if you must): If you are in a hurry, see if the printer offers rush service. Many do, but it will cost extra. Also, some printing methods are faster than others – for instance, DTF might fulfill quicker for a small batch than setting up screen printing. Explain your deadline and see what’s feasible. Just remember, rushing increases the chance of mistakes (less time to fix errors or do quality checks).

• Plan for potential delays: Even if you get a promised date, wise planners add a buffer. There could be unforeseen delays – a blizzard could slow shipping, a supplier could run out of the shirt color you wanted, or equipment might break down. It’s not common, but it happens. If your event is on a Friday, don’t schedule the delivery for Friday morning; try to have it by Wednesday or Thursday. This way if something goes awry, you have a bit of breathing room.

• Avoid last-minute changes: Frequently, delays occur because the design or order details weren’t finalized. Each change can reset the clock (for example, a modified design might need a new proof approval). So, try to lock in your design and quantities early, and then let the production run its course.

• Order a few extra shirts: Another aspect of planning – quantity. It’s often wise to order slightly more than you need (about 5% extra) in case of last-minute additions or printing errors. If you have exactly 100 people and you order 100 shirts, what happens if one print is off-center or a new person joins last second? By having a handful of spares, you’re protected. Plus, you can always use leftovers as future giveaways or keep them as backups. Running out of shirts or scrambling for an emergency reprint is something you can easily avoid with a little foresight.

In short, time is your friend when ordering custom apparel. By starting early and understanding the production timeline, you won’t be caught empty-handed on the big day. Give yourself (and your printer) the gift of time to do things right, and your project will be far less stressful.

Mistake #7: Not Checking Proofs or Testing a Sample First

You’ve done everything right – chose a good vendor, a quality shirt, a great design, planned ahead – now don’t trip at the finish line! The final big mistake is not reviewing the proof or skipping a sample test run before the full order is printed. Once all those shirts are printed, it’s obviously too late to fix anything. You’d be surprised how many people just say “Looks good, go ahead” without really scrutinizing the proof, or they decline a physical sample when ordering in huge volume to save a bit of time or money. This is a classic case of being penny wise and pound foolish.

What can go wrong: Maybe there was a typo in your design (ouch – spelling your company name wrong on 500 shirts is not a good look). Or perhaps the colors on the proof looked fine on your phone screen, but in reality the blue is much darker than you thought. Sometimes alignment can be off slightly, or a small element you didn’t notice is actually printing weird. If you don’t catch it in the proof or via a sample, you’ll catch it when you open the box… and then it’s too late. For big orders, not testing one first is risky – you’re essentially betting thousands of dollars that everything in the digital world will translate perfectly to fabric on the first try.

How to avoid it:

• Always get a digital proof and check every detail: A proof is usually a mockup image of your shirt with the design, sometimes with close-ups or dimensions. Take your time and inspect it. Check that all text is correct (spelling, dates, website URLs – whatever’s on there). Compare the colors to a Pantone book or a known reference if color accuracy is critical – keep in mind screen colors vary, so you might ask the printer about color matches if you have specific brand colors. Ensure the placement and size look right. If something is unclear on the proof, ask questions. It’s perfectly fine to request a slight adjustment or clarification. It’s your last chance to get it right before production. As one printing pro emphasized, reviewing your proof carefully helps prevent expensive errors in the final run.

• Ask for a pre-production sample (for large orders): If you’re doing a large bulk order (for example, 500 company shirts or an order for a paid merchandise line), see if you can get one shirt printed as a sample first and sent to you. Yes, this might cost a little extra and add time, but catching an issue in one sample is so much better than discovering it after 500 are done. You can check the physical sample for print quality, shirt quality, sizing, etc. Many printers will allow a sample run, especially for big jobs – some even insist on it. If a physical sample isn’t possible, at least a detailed proof or even a short run of a few units could be considered.

• Use online design previews: Some custom t-shirt services offer online design tools where you can upload your art and preview it on different shirt sizes and colors. While not 100% accurate, these tools give a decent idea of how your final product will look. It’s a good way to catch obvious issues (like “oh no, that yellow text is unreadable on a white shirt” or “the logo is much smaller than I thought”).

• Double-check everything, then approve: It can be exciting to finally place the order and just “get it done,” but don’t rush the final checks. It’s like proofreading an important document – a little time here can save a lot of regret later. If possible, have someone else on your team also review the proof; a fresh pair of eyes might catch something you overlooked.

Taking this final step seriously separates the amateurs from the pros in custom apparel ordering. By insisting on proofs and samples, you’re ensuring that what you envisioned is exactly what you’ll get. It’s so worth it to avoid the nightmare of opening up your delivery and saying “Uh-oh… that’s not right.”

Ready to Make Awesome Custom Shirts?

You’ve now got the knowledge to dodge the most common pitfalls and order custom t-shirts with confidence. The next step is putting it into action! Whether you’re a business owner gearing up for a marketing push, a team manager outfitting your crew, or a first-timer nervous about getting everything right, you don’t have to go it alone. Our team at Kavy’s Customs is here to guide you through every step – from choosing the perfect shirt and print method to triple-checking that your design is flawless.

Don’t waste money on mistakes. Let’s work together to create custom t shirts that make people say “Wow, I love this shirt!” and wear it again and again. Ready to get started? Contact Kavy’s Customs today for a free consultation or quote. We’ll help you avoid all these mistakes and ensure your custom shirts come out exactly as you imagined (or even better). It’s time to bring your vision to life and get those awesome custom shirts into your hands!

Conclusion

Ordering custom t-shirts can feel intimidating, but it doesn’t have to be a horror story. Let’s recap the keys to success: plan ahead, choose quality, communicate clearly, and double-check everything. Avoiding these seven mistakes – from skipping research and settling for cheap materials to ignoring artwork prep and proofs – will save you time, money, and plenty of frustration. Instead of a box of regrets, you’ll have a batch of fantastic custom shirts that serve their purpose: promoting your brand or cause, boosting team spirit, or delighting your customers.

In the booming world of custom apparel (a market worth billions of dollars and growing), it pays to do it right. Remember, a great custom t-shirt is more than just a piece of clothing – it’s a statement about your brand and a potential favorite item in someone’s wardrobe. By heeding the advice above, you’ll ensure your shirts hit the mark. Now, armed with this knowledge, go forth and create custom shirts that everyone will be excited to wear. Here’s to your successful (and mistake-free) custom t-shirt journey!