Rush Orders: How Fast Can Custom Apparel Be Made?

You have an event in 5 days and just realized you need 100 custom t-shirts. Or a client calls Friday needing branded polos by Wednesday. We get these calls every week at French Press Custom — and yes, we can make it happen.

Here is everything you need to know about rush orders for custom apparel.

Standard vs Rush Timelines

Standard Production Timeline

| Phase | Timeline | |-------|----------| | Art approval + proofing | 1-3 business days | | Screen setup / prep | 1-2 business days | | Printing | 3-5 business days | | Finishing + QC | 1 business day | | Shipping | 2-5 business days | | Total | 8-16 business days |

Rush Production Timeline

| Phase | Timeline | |-------|----------| | Art approval | Same day (if art is ready) | | Screen setup / prep | Same day | | Printing | 1-3 business days | | Finishing + QC | Same day | | Shipping | 1-2 business days (expedited) | | Total | 3-5 business days |

Emergency / Same-Week Timeline

| Phase | Timeline | |-------|----------| | Art approval | Immediate | | Production | 24-48 hours | | Shipping or pickup | Same day / next day | | Total | 1-3 business days |

What Affects Rush Availability

Factors We Control

Press schedule — if we have press availability, we can squeeze your job in
Ink and screen prep — we stock common Pantone colors and can prep screens in hours
Staffing — we can run additional shifts for emergency orders

Factors We Cannot Control

Blank garment availability — if your preferred shirt is not in stock at the distributor, we cannot print on it. We keep popular blanks in stock but specialty colors and sizes may require substitution
Artwork readiness — if your files need significant rework, that adds time even on a rush
Quantity — 50 shirts can be rushed easily. 5,000 shirts cannot be rushed into 2 days

Rush Pricing

Rush production costs more because it disrupts our scheduled workflow and may require overtime labor. Here is what to expect:

| Rush Level | Timeline | Surcharge | |-----------|----------|-----------| | Priority (5-7 days) | Just moved to front of line | +15-20% | | Rush (3-4 days) | Expedited everything | +25-35% | | Emergency (1-2 days) | All hands on deck | +40-75% |

Additionally, shipping costs increase for expedited delivery:

Standard ground: $8-15 (5-7 days)
2-day shipping: $25-50
Overnight shipping: $50-150+ (depends on package weight)
Local pickup: Free (Santa Fe Springs, CA)

Tips for Successful Rush Orders

1. Have Your Artwork Ready

The number one delay on rush orders is waiting for artwork approval. Have your design finalized in a print-ready format (vector AI/EPS/SVG or 300+ DPI PNG) before calling.

2. Be Flexible on Blanks

Your first choice garment might not be available for immediate pull from the distributor. Be open to alternatives:

Instead of Bella+Canvas 3001 in that specific heather color, maybe black or white works
Instead of Comfort Colors, maybe a Gildan Hammer or similar weight
We will suggest the closest available option

3. Simplify the Design

A 1-2 color design is faster to set up and print than a 6-color masterpiece. If speed is the priority, simplify where you can.

4. Call, Do Not Email

Rush orders require real-time communication. Call us at (562) 407-3800 so we can check press availability, blank inventory, and give you an accurate timeline immediately.

5. Approve Proofs Quickly

We will send a digital proof within hours. Approve it immediately to keep the timeline moving. Sitting on a proof for 24 hours defeats the purpose of a rush.

6. Consider Local Pickup

If you are in the Los Angeles / Orange County area, skip shipping entirely. Pick up from our Santa Fe Springs facility and save 2-5 days.

What Can Be Rushed (and What Cannot)

Easy to Rush

Screen printing (1-3 colors) on standard blanks
DTG printing (any color count)
DTF transfers (pre-printed, just need pressing)
Vinyl/HTV names and numbers
Small to medium quantities (12-200 pieces)

Harder to Rush

Embroidery (machine time per piece is fixed)
Sublimation (requires specific polyester blanks that may need ordering)
Large orders (500+ pieces require significant press time)
Specialty inks (puff, metallic — may need to be ordered)
Custom patches (manufactured separately, 2+ week lead time)

Cannot Rush

Custom woven labels (manufactured overseas, 3-4 week minimum)
All-over sublimation on cut-and-sew garments
Custom blanks (special orders from manufacturers)

Real Rush Order Examples

Example 1: Corporate Conference

Situation: 200 polo shirts with embroidered logo needed in 5 business days Solution: Pulled Richardson polos from local stock, ran embroidery on 3 machines simultaneously, shipped via 2-day air Result: Delivered on day 5, +25% rush surcharge

Example 2: Band Show Tomorrow

Situation: 48 t-shirts with a 2-color front print needed in 24 hours Solution: Bella+Canvas 3001 black (in stock), screens burned same morning, printed afternoon, ready for evening pickup Result: Picked up same day, +50% rush surcharge

Example 3: School Fundraiser Reorder

Situation: Spirit wear store sold out, needed 100 more tees in 3 days Solution: Same design, screens on file, Gildan blanks in stock, printed next day, shipped 2-day Result: Delivered in 3 days, +20% rush surcharge

How to Avoid Needing Rush Orders

The best rush order is the one you do not need. Plan ahead:

Events: Order 4-6 weeks before the event date
Corporate: Set up quarterly apparel schedules
Merch: Keep a buffer stock of your best sellers
Schools: Launch spirit wear stores 6+ weeks before delivery deadline
Teams: Order uniforms 3-4 weeks before the season starts

The French Press Custom Rush Guarantee

We do not promise what we cannot deliver. When you call about a rush order, we will give you an honest assessment:

Can we do it? Yes or no.
What will it cost? Clear pricing with no surprises.
What are the trade-offs? (Garment substitutions, simplified design, etc.)

We have been doing this since 2010 and we know our production capacity inside and out.

Need it fast? Call now: (562) 407-3800

Rush Orders: How Fast Can Custom Apparel Be Made?