How to ensure the best quality for my customized shirt?

Ever ordered a custom shirt only to receive a stiff, faded, or poorly printed piece? It happens more often than you think—and it’s preventable.

To ensure the best quality for customized shirts, brands must start with premium fabrics¹, match the right printing method², submit high-resolution artwork³, partner with verified vendors, and maintain clear, proactive communication throughout production.

I learned this the hard way on my first big order. Miscommunication led to pixelated prints and an entire shipment returned. From that day, I built a bulletproof process for quality control—let me show you how it works.

Step 1 – Start with the Right Fabric?

Choosing the right fabric sets the foundation for your shirt’s quality. It affects feel, fit, and print durability.

Use high-grade materials like combed cotton or tri-blend to elevate shirt quality, and avoid cheap substitutes that compromise customer satisfaction.

Heat Press & Color Matching

Choose Premium Fabrics (Combed Cotton, Tri-Blend, Organic Cotton)

• Combed Cotton: Smooth, durable, perfect for DTG.
• Tri-Blend: Luxurious drape and softness for fashion lines.
• Organic Cotton: Adds sustainability value to your brand.

Not all cotton is equal. Carded cotton is rougher and absorbs less ink, causing fading. Combed cotton removes impurities, providing a consistent surface for printing. Organic cotton adds ethical branding, and tri-blends bring comfort and aesthetics together.

Here’s a comparison:

Fabric Type	Softness	Print Quality	Eco-Friendly	Best Use
Combed Cotton	High	Excellent	Moderate	DTG, Screen Printing
Tri-Blend	Very High	Moderate	Low	Fashion, Retail
Organic Cotton	High	Excellent	Very High	Sustainable Lifestyle Brands

Understand GSM: What Weight Means for Durability and Feel

GSM (grams per square meter) measures fabric density. Higher GSM means thicker, more premium feel.

• 120–150 GSM: Lightweight, ideal for hot climates or layering.
• 160–180 GSM: Mid-weight, perfect for standard tees.
• 190–220 GSM: Heavyweight, premium fashion tees.

Light GSM may reduce costs, but it can feel flimsy and see-through. Premium brands often opt for 180–200 GSM to strike a balance between comfort and luxury. Always request GSM data from your supplier to avoid surprises.

Avoid Common Pitfalls (Cheap cotton, over-stretchy poly)

• Cheap Cotton: Rough, inconsistent, shrinks easily.
• Over-Stretchy Polyester: Warps prints and looks low-end.

Low-cost suppliers may use recycled or irregular cotton yarns that pill after washing. Overly elastic poly fabrics can distort logos and crack prints. I always request fabric swatches or conduct lab tests on samples when in doubt.

Step 2 – Match Printing Method to Fabric Type?

The best print in the wrong fabric is a waste. Printing technique must complement your fabric.

DTG suits cotton, sublimation pairs with polyester, and screen printing works best for large runs on flat, stable surfaces.

DTG on 100% Cotton = Sharp, Colorful Prints

• Ideal for detailed, photographic designs.
• Needs pretreatment for dark fabrics.

DTG printers inject ink directly into the fibers. Combed cotton’s smooth surface gives sharper edges. Pretreatment prevents ink from bleeding or fading. For dark tees, white underbase is essential for color vibrancy.

Sublimation on Polyester = Long-Lasting for Performance Shirts

• Dye bonds with fabric, becomes part of the material.
• Works only on polyester and light-colored garments.

Sublimation is unbeatable for activewear. The print never cracks or peels because it’s embedded in the fiber. But it’s picky—don’t try this on cotton. It’s perfect for all-over prints, like full-wrap tees or jerseys.

Screen Print = Great for Bulk and Flat Surfaces

• Economical for orders over 100 units.
• Best for simple logos, bold graphics.

Screen printing is the industry workhorse. It uses stencils and ink layers to create vivid prints. Blends work well here, especially with water-based or plastisol inks. Avoid ribbed or textured fabrics—they blur fine details.

Step 3 – Provide High-Resolution Artwork?

Blurry or pixelated prints usually stem from poor artwork, not poor machines.

Use 300 DPI raster images or vector formats (AI, EPS, SVG) for crisp, scalable print results.

Use 300 DPI or Vector Format (AI, EPS, SVG)

• 300 DPI = sharp edges in raster (PNG, TIFF).
• Vector = infinite scalability without quality loss.

I always recommend AI or SVG files. They’re editable and don’t lose resolution. For photographic designs, 300 DPI ensures print clarity. Never send files below 150 DPI unless you’re okay with blurry shirts.

Avoid JPEGs or Screenshots from Mobile Apps

• Often low-res and compressed.
• May appear stretched or pixelated when enlarged.

Many clients send screenshots from Canva or Instagram—not enough for print. Always export original files. For clients who insist on JPGs, I request the largest size and double-check dimensions before approval.

Use Mockups and Print Area Guidelines

• Place design in real-scale mockups.
• Respect max print zones (usually 12"x16").

Misaligned or off-center prints are often caused by guesswork. Use official templates. We provide clients with PSD mockups and size guides to prevent layout issues.

Step 4 – Work With a Verified Vendor?

Even the best designs can flop with the wrong manufacturer.

Always check factory credentials, order samples, and review past client feedback before placing a bulk order.

Check Certifications (ISO, OEKO-TEX, BSCI)

• Proves quality, ethics, and safety.
• ISO = process control, OEKO-TEX = chemical safety, BSCI = social responsibility.

These certifications tell you a vendor means business. If a supplier lacks even basic ISO or OEKO-TEX, that’s a red flag. At Modaknits, we’re proud of our verified status—it builds trust and opens doors with premium buyers.

Ask for a Physical Sample Before Bulk

• Test fabric, print, stitching quality.
• Spot issues before mass production.

I once received a beautifully printed digital mockup—but the bulk batch used a thinner fabric. Since then, we never skip samples. In fact, we offer 7-day sampling for clients so they can test and tweak early.

Read Reviews or Case Studies

• Look for long-term clients and repeat business.
• Read into how issues were resolved—not just praise.

A vendor’s response to problems says more than five-star ratings. Ask for case studies, especially from similar industries or markets. We document our success stories to show not just what we do, but how we solve.

Step 5 – Communicate Clearly with Your Supplier?

Most quality issues stem from miscommunication. Clarity is everything.

Confirm specs in writing, review samples, and ask for final QC reports before shipping.

Confirm Color Codes (Pantone Matching)

• Avoid color mismatches from screen to print.
• Pantone ensures consistency across batches.

Monitors lie. Pantone doesn’t. Use Pantone Solid Coated numbers for accuracy. I even keep a physical swatch book on hand for color verification when approving samples.

Approve Digital Proof or Pre-Production Sample

• Spot placement or scale issues early.
• Request both flat lay and on-model previews.

Print size may look different on XS versus XXL. That’s why I insist clients approve scaled mockups. Some also request 3D mockups or 360° videos—small investments that avoid huge mistakes.

Ask for QC Reports Before Shipping

• Inspect stitching, sizing, print quality.
• Includes measurement charts and defect photos.

Final QC is your last defense. We follow AQL (Acceptable Quality Level) standards and share full QC sheets with clients. If you’re not getting reports, you’re flying blind.

Conclusion

Great shirts aren’t lucky accidents. They come from intentional choices—right fabric, right print, right partner. If you plan ahead and stay clear with your supplier, you’ll get results that impress every time.

---