What You Need to Know About T-Shirt Printing for Large Orders

June 18, 2025
Written By MFY IT FIRM

Lorem ipsum dolor sit amet consectetur pulvinar ligula augue quis venenatis. 

Ordering custom t-shirts in bulk is an exciting endeavor for many businesses, organizations, or event planners. Whether you’re outfitting a team, creating branded promotional items, or preparing for a special event, ordering t-shirts in large quantities offers numerous benefits. However, this process can also present challenges, especially when it comes to choosing the right printing method and ensuring that your designs look great across every shirt. In this article, we’ll cover everything you need to know about t-shirt printing for large orders so that you can confidently move forward with your bulk printing project.

Understanding Large-Scale T-Shirt Printing

A large t-shirt order typically refers to purchasing 100 or more shirts. This is a common threshold where bulk discounts become significant, and the complexity of the order starts to impact the process. The need for large orders often arises in a variety of situations—corporate events, sports teams, charity fundraisers, or brand promotions.

Ordering t-shirts in bulk can provide several advantages, with the most notable being cost savings. The larger the order, the less you’ll pay per shirt, making it an affordable option for organizations looking to create a lasting impression. Additionally, a bulk order ensures that all t-shirts match in design and quality, contributing to a cohesive and professional appearance.

Choosing the Right Printing Method for Large Orders

The printing method you choose will have a significant impact on the cost, quality, and overall look of your t-shirts. Different printing techniques are suited to different kinds of designs and order sizes, so it’s important to understand the best options for large orders.

Screen Printing

Screen printing is a time-tested and highly popular method for bulk t-shirt printing. It is cost-effective when producing large quantities of shirts, especially for simple designs. The process involves transferring ink through a mesh screen onto the fabric, making it ideal for designs with minimal colors.

For large orders, screen printing is often the best choice due to its efficiency and cost-effectiveness. As the order size increases, the cost per unit decreases, which helps businesses save money. The result is durable prints that can withstand numerous washes without fading. However, screen printing may not be the best choice for intricate or multi-colored designs, as the setup process can be more complex and time-consuming.

Direct-to-Garment (DTG) Printing

DTG printing is a relatively newer method that uses inkjet technology to print designs directly onto the fabric. This process allows for highly detailed and colorful designs, making it an excellent option for shirts with intricate artwork or gradients. While it’s often used for smaller orders, DTG printing can still be a viable option for larger batches depending on the complexity of the design.

One of the benefits of DTG printing is its ability to handle a wide range of designs without requiring setup time for each shirt. However, it’s typically more expensive than screen printing for larger orders, and it may not be as cost-efficient when compared to other methods.

Heat Transfer and Vinyl Printing

Heat transfer and vinyl printing methods are commonly used for smaller or custom projects, but they may not be the best fit for large orders. These methods involve applying heat to transfer a design onto the shirt, either by printing it on a transfer paper (heat transfer) or cutting the design from vinyl (vinyl printing). While these techniques can produce high-quality results for individual designs or small batches, they are not ideal for large quantities. The cost per shirt tends to be higher, and the production time is longer compared to screen printing or DTG printing.

For businesses or organizations looking to create custom t-shirts in bulk, these methods are generally better suited for low-volume, high-quality prints rather than mass production.

Design Considerations for Bulk T-Shirt Printing

Designing custom t-shirts for a large order comes with some important considerations. The key to ensuring that your designs turn out beautifully across every shirt lies in both simplicity and attention to detail.

Keep It Simple

For large orders, simpler designs often yield the best results. The more intricate the design, the more costly and time-consuming the printing process becomes. For large t-shirt orders, it’s beneficial to focus on designs that are easy to reproduce at scale. Opt for bold, clear graphics that are visually striking, and avoid overly detailed illustrations that could be difficult to replicate consistently.

Use High-Quality Files

High-quality design files are essential for producing sharp, crisp prints. When submitting your designs to the printer, make sure they are vector-based files (such as .AI, .EPS, or .SVG formats) as these can be resized without losing quality. High-resolution raster images (like .PNG or .JPEG) may work well too, but they can become pixelated if enlarged beyond a certain point. This is especially important for large orders, where maintaining design consistency across all shirts is crucial.

Work With a Professional Designer

If you’re not a designer, or if your company needs help fine-tuning a design, working with a professional designer can be a great investment. A designer can help refine your design, ensuring that it’s suitable for the t-shirt printing process. They can also help optimize the design for printing methods like screen printing or DTG, ensuring that the final result meets your expectations.

Choosing the Right T-Shirt for Your Large Order

The choice of t-shirt material and style plays a significant role in the final outcome of your printed order. Selecting the right fabric is essential for ensuring comfort, durability, and an overall great look.

Fabric Choices

Cotton is the most popular choice for custom t-shirts due to its comfort, breathability, and print compatibility. For a more durable option, cotton-polyester blends offer the best of both worlds—comfort, breathability, and added strength. If you’re creating t-shirts for an active audience, such as a sports team, moisture-wicking fabrics are ideal, as they keep the wearer dry during physical activity.

Sizing and Fit

When ordering t-shirts in bulk, offering a wide range of sizes is essential. Large orders require careful consideration of different body types and fit preferences. Providing a selection of small, medium, large, and extra-large sizes ensures that everyone can find a shirt that fits well. Pay attention to sizing charts from the printing company to ensure consistency across all shirts.

Working with a Reliable Printer

Choosing the right printing company is crucial for ensuring a smooth, efficient printing process for your large order. Websites like aaprintsupplyco.com offer resources to help you find a reliable printer that understands the ins and outs of large orders. Look for a company with experience in handling bulk printing requests, and be sure to read customer reviews to gauge their quality and service.

Another key factor is turnaround time. Be clear with your printing company about your deadline, and ensure that all design files and specifications are submitted in advance to avoid last-minute delays.

Overcoming Challenges in Large T-Shirt Orders

Even with careful planning, challenges can arise when printing large orders. One of the most common issues is ensuring that all shirts match in color and design placement. To avoid inconsistencies, request a sample or proof from the printer before production begins. This way, you can make any necessary adjustments and ensure that every shirt matches your expectations.

Missed deadlines can also be a concern, so it’s essential to maintain open communication with your printer. Set clear expectations upfront, and stay in touch throughout the process to ensure the order is completed on time.

Conclusion

T-shirt printing for large orders doesn’t have to be overwhelming. By understanding the different printing methods, choosing the right design, and working with a reliable printer, you can successfully complete your bulk order with ease. Whether you’re creating custom apparel for a corporate event, a team, or a promotional campaign, the key to success is careful planning and selecting the best options to suit your needs. With the right approach, you can create high-quality, durable t-shirts that everyone will love.

How to Address Online Reputation Issues Without Going Dark

The Benefits of Implementing Knowledge Management in The Utility Sector

Leave a Comment