10 Common Mistakes When Ordering Custom Apparel
After 15 years and tens of thousands of orders at French Press Custom, we have seen every mistake in the book. Some cost a few dollars, others cost thousands. The good news? They are all avoidable.
Here are the 10 most common mistakes and how to dodge them.
1. Submitting Low-Resolution Artwork
The mistake: Sending a tiny JPEG pulled from your website, a screenshot from Instagram, or a Word document with your logo pasted in. These files are 72-150 DPI — far too low for quality printing.
The result: Blurry, pixelated, fuzzy prints. Or your printer spends time (and charges you) to recreate the artwork.
The fix: Always provide vector files (AI, EPS, SVG) or high-resolution rasters (300+ DPI PNG at actual print size). If you do not have the original files, ask the designer who created your logo. If that is not possible, budget for artwork recreation ($45-125).
2. Ordering the Wrong Sizes
The mistake: Guessing at sizes without measuring, not accounting for sizing differences between blank brands, or using a "one size chart fits all" mentality.
The result: Shirts that do not fit. Wasted inventory. Unhappy recipients. Emergency reorders.
The fix:
- Collect sizes from actual wearers whenever possible
- Reference the specific blank's size chart (Bella+Canvas runs smaller than Gildan)
- Order a sample set to try on before committing
- Order 10% extra in popular sizes (L, XL) for errors
- When in doubt, size up
3. Not Specifying Pantone Colors
The mistake: Telling your printer "I want blue" or sending a hex code (#3B82F6) and expecting an exact match.
The result: The "blue" your printer mixes is not the blue you imagined. Your brand looks inconsistent across different print runs.
The fix: Provide Pantone (PMS) color numbers for every color in your design. If you do not know your Pantone colors, ask your printer to help you match from a physical Pantone guide.
4. Ignoring the Blank Garment Quality
The mistake: Choosing the cheapest blank available to save $2 per shirt, then wondering why your custom apparel feels like a dishrag.
The result: Boxy fit, rough fabric, shrinkage after washing. Your employees, customers, or event attendees wear the shirt once (if ever) and toss it.
The fix: The blank IS the product. Budget for quality:
- Budget events: Gildan 5000 ($2-3) is acceptable
- Brand merch: Bella+Canvas 3001 ($4-6) minimum
- Premium gifts: Comfort Colors 1717, Champion, Nike ($5-25)
The $3 difference per shirt is the difference between "worn once" and "favorite shirt."
5. Ordering Too Many (or Too Few)
The mistake: Over-ordering 500 shirts "just in case" and ending up with 200 unsold. Or under-ordering 50 when you needed 75 and paying rush fees for the reorder.
The result: Wasted money on dead inventory or expensive rush reorders.
The fix:
- Start with your confirmed count + 10-15% buffer
- Use pre-orders or online stores to collect exact quantities before printing
- Remember: screen printing has price breaks at specific quantities (24, 48, 72, 144). Order at or slightly above a break point for best per-unit price.
6. Waiting Until the Last Minute
The mistake: Calling two weeks before an event to order 200 custom shirts.
The result: Rush fees (25-75% surcharge), limited blank availability, no time for revisions, and maximum stress for everyone.
The fix: Plan 4-8 weeks ahead for standard orders. See our event timeline guide for specific planning windows. If you are already behind schedule, call us — we can often make it work, but earlier is always better and cheaper.
7. Too Many Colors in the Design
The mistake: Submitting a 12-color design with gradients, drop shadows, and photographic elements for screen printing.
The result: Sticker shock when the quote comes back (12 screens = $300+ in setup alone), plus higher per-unit costs.
The fix:
- Simplify designs for screen printing to 1-4 colors
- If your design requires many colors, consider DTG, DTF, or simulated process
- Ask your printer to recommend the best method for your artwork
- A bold 2-color design often looks better than a busy 8-color one
8. Not Getting a Proof
The mistake: Approving your order without seeing a digital mockup of the final product. "It is just my logo on a black shirt — it will be fine."
The result: The logo is smaller (or larger) than expected. The placement is off. The color looks different on black than you imagined.
The fix: Always request a digital proof showing your exact design on the exact garment color. Review it carefully for:
- Size and placement
- Color accuracy
- Text spelling (check three times)
- Print locations (front, back, sleeve positions)
Approve in writing. A good printer will not produce without written proof approval.
9. Forgetting About Additional Costs
The mistake: Getting a quote for "$8 per shirt," ordering 100, then being surprised by the final invoice that includes setup fees, art charges, shipping, and tax.
The result: Budget overrun and a frustrating experience.
The fix: Make sure your quote includes ALL costs:
- Blank garment cost
- Printing/decoration cost
- Screen/digitizing setup fees
- Art charges (if files need work)
- Packaging (if needed)
- Shipping
- Tax
At French Press Custom, our quotes are all-inclusive. Ask upfront what is and is not included.
10. Not Planning for Reorders
The mistake: Treating your first order as a one-time purchase when you know you will need more later (new employees, events, restocking merch).
The result: Starting from scratch each time, potentially getting inconsistent results, and missing opportunities to save on setup.
The fix:
- Keep your screen/digitizing files on record with your printer (we save everything)
- Order extra blanks at the initial production run (they are cheapest in bulk)
- Set up a reorder schedule (quarterly is common for corporate)
- Consider an online store for ongoing orders (new hires, replacement stock)
- Ask about screen storage — most shops keep screens for 6-12 months
Bonus: Not Communicating Your Timeline
The mistake: Not telling your printer when you actually need the order. "As soon as possible" is not a timeline.
The fix: Give your printer a specific delivery date or event date. This allows them to:
- Schedule your job appropriately
- Alert you to potential timeline conflicts
- Recommend rush options if needed
- Plan shipping to arrive with buffer time
The Summary
| Mistake | Quick Fix | |---------|-----------| | Low-res artwork | Send vector (AI/EPS/SVG) or 300+ DPI | | Wrong sizes | Collect from wearers + order samples | | No Pantone colors | Specify PMS numbers | | Cheap blanks | Budget $4-6 for quality tees | | Wrong quantities | Pre-order + 10% buffer | | Last minute | Plan 4-8 weeks ahead | | Too many colors | Simplify to 2-4 for screen print | | No proof review | Always approve a mockup | | Hidden costs | Get all-inclusive quotes | | No reorder plan | Keep files, set schedule |
Work with French Press Custom
We help our clients avoid all of these mistakes through clear communication, expert guidance, and a process refined over 15 years and thousands of orders.
First time ordering custom apparel? Call us at (562) 407-3800 or fill out our quote form. We will walk you through every step so your first order is a great experience.
