10 Common Mistakes When Ordering Custom Apparel (And How to Avoid Them)

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

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.