7 T-Shirt Printing Errors to Avoid When Placing Custom Orders

Ordering custom t-shirts should be exciting. Whether it’s for a company event, sports team, fundraiser, or promotional giveaway, a well-printed shirt brings your vision to life. But many customers run into preventable mistakes that affect quality, cost, or timing. By knowing the most common t-shirt printing errors, you’ll be better prepared to avoid frustration and get exactly what you want. Let’s walk through the custom apparel ordering mistakes we see most often, and how to sidestep them with confidence.

1. Choosing the Wrong Printing Method

The first decision is how your design will be applied. Screen printing, digital printing (DTG), and heat transfer all have their place.

Why It Matters

Screen printing is often the best choice for bulk orders because it provides long-lasting, vibrant colors and becomes more cost-effective as the order grows. DTG works better for small runs or designs with lots of color detail. Heat transfer is useful for personalization, like names or numbers, but it is not always durable for heavy wear. If you don’t align the method with your needs, you risk higher costs or lower-quality results.

2. Submitting Low-Resolution Artwork

Your design is only as good as the file you provide. One of the most common t-shirt printing errors comes from sending blurry, low-resolution images.

Why It Matters

Printers need high-quality files to ensure clean lines and sharp colors. A pixelated logo on your computer screen will look even worse stretched across fabric. Always provide vector files when possible or confirm with your printer that the resolution is adequate.

3. Ignoring Fabric Type

Different fabrics interact with ink in different ways, and this can make or break your order.

Why It Matters

Screen printing inks work great on cotton, while blends may require special handling. A design that looks amazing on a cotton tee may not show up as vividly on polyester. The fabric also impacts comfort and durability. Choosing the wrong material for your design is one of the most overlooked t-shirt printing errors.

4. Miscalculating Order Volume

Many customers underestimate how many shirts they’ll need.

Why It Matters

Ordering too few can lead to higher costs if you need a second run. Ordering too many can strain your budget. Order volume also impacts your price per shirt, so it’s worth planning ahead with your team or group to lock down numbers early.

5. Skipping the Proofing Process

The digital proof is your last chance to catch mistakes before production.

Why It Matters

Skipping this step or glancing too quickly can lead to spelling mistakes, color mismatches, or logo placement issues. Take the time to review your proof carefully, because once it’s on the shirt, it’s permanent.

6. Overcomplicating the Design

A complicated design might look good in theory but can be difficult to execute on fabric.

Why It Matters

Too many fine details or colors can raise costs and reduce clarity. Simpler designs often look sharper and last longer. When in doubt, streamline your graphics to focus on what matters most.

7. Not Accounting for Lead Times

Rush jobs can increase costs and limit your options.

Why It Matters

Every printer has production schedules, especially during busy seasons. One of the most costly t-shirt printing errors is waiting too long to order. Planning ahead ensures you get the quality you want at a price that makes sense.

Avoiding t-shirt printing errors is easier when you work with a trusted partner. At Marathon Sportswear, we walk you through every step. Discover more.

Our Custom T-Shirts

Custom T-Shirt Printing Tips

When planning your next custom order, a few extra steps can make the process even smoother.

Always confirm sizing charts with your printer to avoid unexpected fit issues.
Request a fabric sample before committing, especially if comfort is a priority.
Think about long-term wear and choose colors that won’t fade quickly.
Ask about eco-friendly inks or fabrics if sustainability matters to your audience.
Store your shirts properly after delivery to preserve print quality.
Build in extra time for shipping so you’re never caught in a rush.

Partner with Marathon Sportswear for Stress-Free Custom Orders

The best way to avoid t-shirt printing errors is to plan ahead, keep designs simple, and choose the right partner. Marathon Sportswear has decades of experience helping schools, businesses, and organizations across Chicagoland create apparel that looks great and lasts. Get in touch today to get the process started.