How T Shirts Are Printed: A Practical Guide for Bulk Custom T-Shirt Printing

June 26, 2025

T-shirts speak for your brand before anyone does. Whether it’s a college event, a corporate campaign, or your everyday staff uniform, the way a shirt is printed can shape how your team looks and feels. That’s why knowing how t shirts are printed matters when you’re ordering in bulk.

At Unitees, we work with businesses, colleges, and organizations that need reliable custom printing. This guide will help you understand the most used printing methods for bulk orders, so you can choose what suits your logo, budget, and delivery timeline best.

The Most Trusted Printing Methods Used by Unitees

1. Screen Printing – Best for Bulk Orders with Simple Designs

Screen printing is one of the most widely used methods. It applies ink to fabric using a mesh screen and is perfect for large orders with minimal design variation.

Best suited for:

Startups placing large orders with the same design
Simple logos with fewer colors
Promotional giveaways or team uniforms

Why it works:
It offers consistent quality in large volumes and reduces per-unit cost as the order increases. It’s long-lasting and bold, holding up well after many washes.

2. DTG (Direct to Garment) – Ideal for Detailed Artwork in Small Batches

DTG uses a printer to apply ink directly onto the fabric. Think of it as printing on paper, but for t-shirts. It works best for complex, colorful designs.

Best suited for:

Brands with detailed artwork or photo prints
Custom t-shirts with multiple color gradients
Low-volume orders that need rich visuals

Why it works:
DTG delivers high-resolution prints without setup costs. It’s perfect when your design has lots of detail or when every shirt is different.

3. Vinyl Printing – Great for Names, Numbers & Short Runs

Vinyl printing uses heat transfer to apply cut vinyl designs to t-shirts. It’s often used for personalized prints or short-term branding needs.

Best suited for:

Sports teams need player names and jersey numbers
Event merchandise with custom text
Short runs with minimal graphic changes

Why it works:
Vinyl printing produces a clean, durable finish and works well across different fabrics. It’s excellent for customization without large setup costs.

How T Shirts Are Printed Step-by-Step for Bulk Orders

The Unitees Printing Process – Clear, Simple, Reliable

Purpose: To give every brand or organization a trusted way to bring their t-shirt design to life with quality, speed, and consistency.

Here’s how the full process works from start to finish when you place a bulk custom apparel order with Unitees:

1. Design Consultation and Idea Finalization

Goal: Understand what the customer wants—style, branding, color, and quantity.

Resource: Our in-house creative team works with you to finalize designs, positioning, and color codes.

Output: A clear mockup of your custom t-shirt, polo, or sweatshirt for approval.

Flexibility: You can submit your own designs or work with our designers from scratch.

2. Selecting the Right Printing Method

Decision: Based on your order size, design complexity, and fabric type, we recommend the best method.

Screen Printing for bold, repeat designs
DTG for colorful and detailed artwork
Vinyl Printing for individual customization
Embroidery for a premium touch on polos and uniforms
Support: Our team helps you weigh durability, budget, and visual style to pick the right option.

3. Fabric and Product Selection

Options: Choose from t-shirts, polos, sweatshirts, or custom styles.

Materials: Cotton, poly-cotton blends, and moisture-wicking fabrics
Fit Choices: Regular, slim fit, unisex, or gender-specific
Colors: Large stock of standard shades + custom dye options (on request)

Note: This is where most company polo shirts with logo and business t shirts with logo orders are finalized with product type, fabric, and finish.

4. Sampling (Optional but Recommended for Bulk)

Preview: You can request a sample before full production begins.

What’s Included: One printed unit with your final design
Benefit: Confirms color, size, print clarity, and material feel

Best Practice: Most corporates and colleges request this for large quantity orders.

5. Bulk Printing and Quality Checks

Process: Once approved, production begins.

Production Time: Typically 5–10 working days depending on volume

Checks:

Print alignment and color match
Fabric quality inspection
Logo and design accuracy

Quality Standard: Every unit is checked to ensure consistency across the full batch.

6. Packing and Delivery

Packing: Shirts are folded, packed by size and design, and labeled as per client requirements.

Delivery Options:

Bulk dispatch to one or more locations
Scheduled delivery for events, campaigns, or staggered rollouts

Final Touch: You receive your order ready to wear, distribute, or sell—on time, every time.

Embroidery – For Premium Branding on Polos and Sweatshirts

Embroidery is often chosen by companies that want a professional and long-lasting look for their uniforms. Instead of printing ink onto fabric, embroidery uses thread to stitch your logo or text directly into the material. This gives a raised, detailed finish that doesn’t fade or peel, even after many washes.

At Unitees, embroidery is a popular option for company polos, team sweatshirts, and jackets where durability and presentation matter. It works best on thicker fabrics like cotton polos or fleece, where the stitching holds shape and adds visual weight. It’s often the preferred choice for brands looking to create smart, consistent uniforms for employees or field staff.

While embroidery gives a high-end appearance, it works best when the design is simple, with solid colors and clean shapes. Very small text or highly detailed artwork may not translate well into thread. But if your focus is to make your staff stand out with a sharp and polished identity, embroidery does the job well and lasts long.

Industry-Specific Recommendations for Custom T-Shirt Printing

Every industry has different requirements when it comes to uniforms or branded apparel. From fabric choice to printing method, your decision should be based on how and where the apparel will be used. Below are tailored recommendations for each type of business or organization Unitees serves.

Corporate Offices & Enterprise Teams

Uniforms for office staff and corporate teams must balance comfort, branding, and presentation. They are often worn daily and must reflect professionalism. When selecting business t shirts with logo, keep the following points in mind:

Use cotton polo shirts with embroidery or screen printing for a neat, premium look.
Stick to minimal designs that match your company colors for brand consistency.
Choose medium to heavyweight fabric that holds structure and resists wrinkling.
Include company logos on the chest and optionally on the sleeve for brand visibility.
Keep the fit slightly relaxed for comfort across diverse team roles.

Colleges, Fests & Event Organizers

College events, festivals, and promotional campaigns usually require budget-friendly apparel that’s vibrant, wearable, and easy to distribute in bulk.

Go with screen printing on light cotton t-shirts for cost-effective mass production.
Use bright background colors and bold text to stand out in large crowds.
Keep the design simple to reduce printing cost and speed up production.
Consider unisex sizing to simplify inventory and distribution.
Use tear-away labels or tagless options for comfort during long hours of wear.

Sports Teams & Marathons

Activewear needs to handle sweat, movement, and constant washing. Whether for a school sports team or a sponsored city marathon, comfort and durability matter most.

Choose performance fabric or polyester blends that wick moisture and stay lightweight.
Use vinyl printing for individual names and jersey numbers.
Keep the fit flexible to allow ease of movement.
Go for contrasting text colors for visibility in outdoor use.
Double-check sizing for all players beforehand to avoid last-minute issues.

NGOs, Field Teams & Awareness Campaigns

T-shirts for awareness drives or NGO workers need to be functional, affordable, and clear in messaging—especially when used in outdoor or public settings.

Use screen printing on budget cotton fabrics for maximum quantity at low cost.
Prioritize bold and readable messaging across the front and back.
Stick to two-color designs to reduce printing time and pricing.
Offer light colors in summer and darker tones in winter for comfort.
Keep fit relaxed to suit volunteers of all sizes and activities.

Delivery & Logistics Staff

Work uniforms for logistics, warehouse, and delivery teams require long-lasting material and clear branding. The apparel must stay strong through rough use.

Go for polo shirts or durable tees with embroidery for long-term visibility.
Use dark colors to hide stains and reduce the need for frequent replacements.
Prioritize stretchable cotton blends for flexibility and comfort.
Include branding on both front and back for maximum exposure during deliveries.
Reinforce high-friction areas like shoulder seams and collars to improve durability.

Conclusion

Knowing how t shirts are printed helps businesses make smart, confident choices when ordering in bulk. Whether you're sourcing uniforms for your staff, creating event merchandise, or setting up branded apparel for promotions, the right printing method makes all the difference. It affects not just how the final product looks, but how it performs day after day. From screen and vinyl to embroidery and DTG, every technique serves a specific purpose—and at Unitees, we help you match the right method to your unique needs.

Our job doesn’t end at printing. We support you with design consultation, product selection, and full-service production to deliver what your team actually needs. Whether you're ordering company polo shirts with logo or a full run of business t shirts with logo for your next event, Unitees is here to simplify the process. No compromises on quality, no surprises on timelines—just professional, custom clothing done right.

Back to blog