Ordering custom printed workwear is an exciting step for any business, but it’s also one that requires careful consideration. Whether you’re outfitting a small team or an entire workforce, avoiding these common pitfalls can save you time, money, and disappointment. Here are five mistakes we frequently see, and how to avoid them.
Skipping the Sample Stage
One of the biggest mistakes businesses make is ordering in bulk without testing a sample first. What looks perfect on screen might not translate well to fabric. Colours can appear different, sizing may vary between brands, and the quality of the garment might not meet your expectations.
Always order a sample with your logo printed or embroidered on it before committing to a large batch. This allows you to assess the quality, check how your design looks on the actual fabric, and ensure the sizing works for your team. Yes, it adds a bit of time to the process, but it’s far better than receiving 50 garments that aren’t quite right.
Providing Low-Resolution Artwork
Your logo is the face of your brand, so it needs to look sharp on your workwear. Submitting low-resolution images, screenshots, or files pulled from your website is a recipe for disappointment. These files simply don’t contain enough detail to produce crisp, professional-looking prints or embroidery.
For the best results, provide your printer with vector files (such as AI, EPS, or PDF formats) or high-resolution images (at least 300 DPI). If you’re unsure about your file quality, ask your printing company beforehand—most will review your artwork and advise if it needs improvement. Taking the time to get this right ensures your branding looks as professional as you intended.
Ignoring Fabric Compatibility
Not all printing methods work equally well on all fabrics. For instance, Direct to Film (DTF) printing excels on polyester and synthetic blends but may not be ideal for 100% cotton garments. Similarly, embroidery works beautifully on polos and jackets, but can look too heavy on lightweight t-shirts.
Before placing your order, discuss the fabric composition of your chosen garments with your printing company. They can recommend the best decoration method based on the material. Understanding this relationship between fabric and printing technique ensures your designs look their best and last longer through repeated washing and wear.
Getting Sizing Wrong
Ordering workwear without properly measuring your team is a costly mistake. Different brands fit differently, and what’s a “medium” in one range might be closer to a “large” in another. Guessing sizes often results in garments that are too tight, too loose, or simply unwearable.
Request size charts from your supplier and compare them against your team’s measurements. Better yet, order a range of sample sizes for your team to try on before finalising the order. Considering body types and preferences, some people prefer a looser fit while others like garments more fitted. Getting sizing right means your team will actually wear the workwear, which is the whole point of the investment.
Leaving Insufficient Time
Custom workwear isn’t an off-the-shelf product, it requires design approval, production time, and often multiple rounds of communication. Rushing the process because you need the garments “yesterday” typically leads to mistakes, compromises on quality, or paying premium rates for rush orders.
Plan and allow adequate time for the entire process. A typical timeline includes artwork preparation and approval, sample production (if requested), bulk production, quality checking, and delivery. Depending on order size and complexity, this can take anywhere from two to four weeks. Starting early gives you breathing room to get everything right and avoid the stress of last-minute panic.
Get It Right First Time
Ordering custom printed workwear doesn’t have to be complicated. By avoiding these five common mistakes, you’ll end up with professional, high-quality garments that your team will be proud to wear. Remember: investing a little extra time in planning, sampling, and communication upfront saves significant headaches down the line.
The key is working with an experienced printing company that understands these challenges and guides you through each step of the process. Don’t hesitate to ask questions, request samples, and seek advice—a good supplier wants your order to succeed just as much as you do.
Ready to Order Custom Workwear?
At Printreloaded, we make the ordering process simple and stress-free. Our experienced team will guide you through every step, from choosing the right garments to perfecting your artwork.