Design With the End Product in Mind
A t-shirt design that looks good on a computer screen does not always print well on fabric. Colors shift. Fine details disappear. Text that reads clearly at 100% scale becomes illegible when reduced to chest size.
At Northwest Custom Apparel in Milton, Washington, we have rejected or reworked thousands of design files over 47 years. We have seen 72 DPI screenshots submitted for embroidery, and neon RGB colors that have no CMYK or Pantone equivalent. We have seen text set in 6-point font that becomes a blur on a shirt.
This guide covers how to design a custom t-shirt that works with our production equipment. Not general design theory. Specific file requirements, color constraints, and placement rules that prevent costly mistakes.
Step 1. Define the Purpose Before You Open a Design Tool
The purpose of the shirt determines every design decision that follows.
| Purpose | Typical Design Approach | Decoration Method |
|---|---|---|
| Employee uniform | Left-chest logo, company name on sleeve | Embroidery |
| Event or charity run | Large front graphic, event name and date | Screen printing |
| Photo memorial or gift | Full-color portrait, no color limit | DTG printing |
| Merchandise for sale | Bold graphic, brand name, retail-quality blank | Screen print or DTG |
| Team or club identity | Mascot or emblem, team name, member names | Screen print with individual name add-on |
Choose your purpose before you choose your colors, fonts, or layout. A design for an embroidered polo requires different thinking than a design for a screen-printed concert tee.
Step 2. Choose the Right Printing Method for Your Design
Your design and your decoration method are not independent choices. They constrain each other.
Screen Printing
Screen printing pushes ink through a mesh screen onto the fabric. It produces the most vivid, opaque color of any method. It is also the most cost-effective for bulk orders.
Design constraints for screen printing:
- Maximum 6 colors per design (each color requires a separate screen)
- Bold, simple graphics work better than fine detail or photographic images
- Halftone dots can simulate shading but require 200+ mesh count and add cost
- Minimum line weight of 1.5 points to prevent ink bleeding
Best for: Event shirts, team uniforms, promotional giveaways, bulk orders of 24+ pieces.
Direct-to-Garment (DTG) Printing
Our Kornit Storm Hexa printer sprays water-based ink directly onto the fabric. It handles unlimited colors, gradients, and photographic detail without screen setup.
Design constraints for DTG:
- 300 DPI minimum for photographic images
- Works best on 100% cotton or high-cotton blends (polyester repels water-based ink)
- White ink base on dark garments adds cost but prevents dye migration
- Fine text below 8 points may lose clarity on textured fabric
Best for: Photo memorials, small-run merchandise, samples, designs with 7+ colors.
Detailed, Durable, Direct-to-Garment Printing
Perfect for intricate designs, small-batch orders, and eye-catching colors. Make your brand vision a reality with DTG printing.
Get Custom DTG Printing SolutionEmbroidery
Our Tajima TMAR-KC 8-head machine stitches thread directly into the fabric. It produces the most durable decoration. It also has the strictest design constraints.
Design constraints for embroidery:
- No gradients or photographic detail (thread is solid color)
- Minimum text height of 0.25 inches (6.4 mm) for readability
- Small text and fine detail require satin stitch, which increases stitch count and cost
- We must digitize your design into a stitch file (DST or PES format) before production
Best for: Employee uniforms, premium apparel, workwear, any garment that sees daily washing.
For more on how we convert your artwork to stitch files, see our logo digitizing service.
Step 3. Create a File That Our Equipment Can Read
File Format Requirements
| Decoration Method | Preferred Format | Acceptable Alternatives | Unacceptable |
|---|---|---|---|
| Screen printing | Vector (AI, EPS, PDF with editable layers) | High-resolution PNG (300 DPI, transparent background) | JPEG, Word document, PowerPoint slide |
| DTG printing | PNG (300 DPI, transparent background) | TIFF, PSD | JPEG with compression artifacts, low-resolution screenshots |
| Embroidery | Vector (AI, EPS, PDF) | High-resolution PNG | JPEG, BMP, scanned sketches |
Color Mode and Matching
Screen printing uses Pantone-matched plastisol ink. We match your design to the closest Pantone Solid Coated color. If your design uses RGB colors from a screen, we convert them. The result may not match what you see on your monitor.
DTG printing uses CMYK process color. We can approximate most RGB colors but cannot match metallic, neon, or fluorescent tones.
Embroidery uses thread colors from our inventory. We carry approximately 250 thread colors. We match your design to the closest available thread. If you need an exact brand color match, we can special-order thread at additional cost and lead time.
Resolution and Detail
- Minimum resolution: 300 DPI at print size for raster images
- Minimum line weight: 1.5 points for screen print, 0.25 inches for embroidery text
- Text size: No smaller than 8 points for screen print or DTG, 0.25 inches for embroidery
- Bleed: Not required for apparel. Designs print within the specified dimensions.
Step 4. Place the Design Correctly on the Garment
Standard Print Locations
| Location | Typical Dimensions | Best For |
|---|---|---|
| Left chest | 3.5 x 3.5 inches | Logos, monograms, small emblems |
| Full front | 12 x 14 inches | Event graphics, large logos, team names |
| Full back | 12 x 14 inches | Event names, sponsor logos, team rosters |
| Sleeve | 2 x 3 inches | Small logos, hashtags, secondary branding |
| Upper back (below collar) | 10 x 3 inches | Company names, event tags |
Consider the Garment Type
A design that works on a flat t-shirt may not work on a curved cap or a zippered hoodie. Seams, pockets, and zippers interrupt the print area.
- Pocket tees: The pocket covers part of the left chest. We either print above the pocket or on the pocket itself.
- Hoodies: The hood covers the upper back. We avoid printing in the area that folds under the hood.
- Caps: The curved panel limits design height. We recommend low-profile designs with minimal text.
- Polos with buttons: The placket splits the chest. We center the design between the buttons or move it to the left chest.
Step 5. Proof Before You Print
We send a digital proof within 24 hours of receiving your design file. The proof shows:
- Exact print dimensions on the garment
- Color callouts (Pantone for screen print, thread color for embroidery, CMYK values for DTG)
- Placement relative to seams, pockets, and other garment features
Review the proof carefully. Check for:
- Typos and spelling errors
- Color accuracy (compare to your brand guidelines)
- Size and placement
- Missing elements or cropped graphics
We do not start production until you approve the proof. Changes after approval may incur additional setup fees.
Common Design Mistakes We See
Low-resolution images. A 72 DPI image from a website becomes pixelated when enlarged to 12 x 14 inches. We reject these files and request higher resolution.
Copyrighted material. We cannot print Disney characters, NFL logos, band album art, or any design you do not own or license. See our copyright guide for t-shirt designs for the legal details. We reserve the right to refuse any order that appears to infringe third-party intellectual property.
Too many colors for screen printing. A 10-color design requires 10 screens, 10 setups, and 10 print passes. The cost increases exponentially. We recommend simplifying to 3 colors for most screen-printed orders.
Fine detail on textured fabric. A design with hairline borders and 6-point text looks crisp on paper. On cotton fleece, the texture swallows the detail. We recommend bold lines and larger text for all apparel applications.
Tools and Resources
You do not need expensive software to create a production-ready design. We accept files from:
- Canva: Export as PNG with transparent background at 300 DPI
- Adobe Illustrator: Save as AI or PDF with fonts outlined
- Adobe Photoshop: Save as PSD or PNG at 300 DPI, layers flattened
- Procreate (iPad): Export as PNG at 300 DPI
If you need design assistance, our in-house team can adapt your sketch or concept into a production-ready file. We do not charge for simple text layouts. Complex design work is billed at $75 per hour.
Frequently Asked Questions
PNG at 300 DPI with a transparent background. JPEG files with compression artifacts or low resolution will not print clearly.
Sometimes. If the JPEG is high resolution (300 DPI at print size) and the design is simple, we can work with it. For complex designs or color-critical logos, we need a vector file or a high-resolution PNG.
For screen printing, we match to Pantone Solid Coated. Send us your Pantone codes. For DTG, we approximate from CMYK values. For embroidery, we match to our thread inventory. If exact color matching is critical, request a physical sample before production.
We will recommend DTG printing for orders under 24 pieces, or we will suggest simplifying the design to 6 colors or fewer for screen printing. We do not recommend screen printing with more than 6 colors unless the order volume justifies the additional setup cost.
Yes. We produce a physical pre-production sample for approval before any bulk run over 48 pieces. For smaller orders, we provide a digital proof. Sample production adds 3–5 business days to the timeline.
Ready to Print Your Design?
We have produced custom t-shirts for Washington businesses since 1977. Every order runs in-house at our Milton, WA facility. We do not outsource to third-party decorators.
Send us your design file for a free review and quote:
Email: sales@nwcustomapparel.com
Call: 253-922-5793
Visit: 2025 Freeman Rd E, Milton, WA 98354
Upload Your Design and Request a Quote →
About the Author
Erik Mickelson is the Operations Manager at Northwest Custom Apparel in Milton, Washington, with 29 years of hands-on experience in embroidery digitizing, screen printing, and custom apparel production. He graduated from Washington State University in 1996 and founded the Apparel Graphic Academy. His father, Jim Mickelson, founded Northwest Custom Apparel in 1977.
