Why First-Time Buyers Make Costly Mistakes
Every week, we see the same mistakes costing Canadian businesses, teams, and organizations hundreds—sometimes thousands—of dollars. The worst part? Nearly all of these mistakes are completely preventable.
Custom apparel seems simple: pick a shirt, add a logo, done. But the details matter enormously. The wrong blank shrinks two sizes. Low-resolution artwork prints blurry. Poor planning means rush order fees that double your costs. A size distribution guess leaves half your team with shirts that don't fit.
We have printed over 2 million custom garments for Canadian customers. We've seen every mistake imaginable—and helped countless first-time buyers avoid them. This guide shares the 10 most common (and costly) errors, with practical solutions that ensure your order turns out perfectly.
Whether you're ordering 20 shirts for a charity run or 500 for your company, this checklist will save you money, time, and headaches.
Not Ordering Samples First
The Risk
You order 200 custom t-shirts based on product photos online. When they arrive, the fabric feels thin and cheap. The color looks completely different than the website showed. The fit runs smaller than expected. Now you're stuck with 200 shirts nobody wants to wear.
Typical Cost Impact
$600-$2,000 wasted on unusable inventory, plus the cost of reordering from scratch. For a 200-shirt order, this mistake can cost $1,200-$2,500 total.
Real Example
"We ordered 150 navy t-shirts for our corporate event. When they arrived, the 'navy' was actually more of a bright royal blue—completely wrong for our brand colors. We had to rush-order replacements at 2x the cost and the event was in 5 days." — Marketing Manager, Toronto
How to Avoid It
The Solution
- Order blank samples of the exact garment style and color before committing to large quantities
- Request a printed sample if your design is complex or uses critical brand colors
- Check the fabric weight, feel, and quality in person—photos lie, samples don't
- Try on different sizes to verify the fit matches your group's needs
- Compare colors in natural daylight, not just indoor lighting
- Invest $20-50 in samples to save $1,000+ on mistakes
Pro Tip
At T-Shirt Elephant, we offer blank samples at cost and printed samples for a nominal fee. We'd rather you love your order than deal with disappointed customers. Ask about our sample program before placing large orders.
Using Low-Resolution Artwork
The Risk
You grab your logo from your website, email it to the printer, and assume it will work. When the shirts arrive, your logo looks pixelated and blurry. Text is fuzzy and hard to read. What looked fine on screen looks terrible on fabric.
Typical Cost Impact
$400-$1,500 for reprint, plus you may need to pay a designer to recreate artwork in proper format ($150-300). Total cost: $550-$1,800.
Understanding Resolution & File Types
| File Type | Best For | Minimum Quality | Notes |
|---|---|---|---|
| Vector (AI, EPS, PDF) | Screen printing, embroidery | N/A (scalable) | Best option—scales infinitely without quality loss |
| High-Res PNG/JPG | DTF printing, full-color designs | 300 DPI at print size | Works if resolution is high enough |
| Web Images | Nothing | Usually 72 DPI | Too low—will print blurry and pixelated |
| Screenshots | Nothing | 72-150 DPI | Never use these for printing |
Real Example
"I sent them the logo from our Facebook page. It looked fine on my computer screen, but when printed on 100 t-shirts, you could see every pixel. We had to scrap them all. Now I know to ask our graphic designer for the 'high-res vector file.'" — Sports Team Manager, Calgary
How to Avoid It
The Solution
- Request vector files (AI, EPS, PDF) from your designer—these scale perfectly
- For raster files (PNG, JPG), ensure 300 DPI at actual print size (e.g., 300 DPI at 12" wide)
- Never use images grabbed from websites, social media, or Google—they're 72 DPI
- If you only have low-res artwork, ask if the printer offers design recreation services
- Review a digital proof before printing—zoom in to check clarity
- Send your files early so the printer has time to request better versions if needed
Pro Tip
We offer free artwork review and will alert you if your file quality is insufficient before we print. We can often recreate simple logos for a small fee. Learn more in our Artwork Requirements Guide.
Choosing the Wrong Decoration Method
The Risk
You choose screen printing for 10 full-color shirts and get shocked by the $500 setup fee. Or you pick the cheapest option without realizing it won't work on your polyester jerseys. Or you order embroidery on lightweight t-shirts that pucker and look terrible.
Typical Cost Impact
$200-800 in unnecessary setup fees, or 30-50% higher per-unit costs by choosing the wrong method for your quantity and design.
Decoration Method Decision Guide
| Method | Best For | Typical Quantity | Cost Structure |
|---|---|---|---|
| Screen Printing | Simple designs, 1-3 spot colors, bulk orders | 24+ pieces | High setup, low per-unit cost |
| DTF Printing | Full-color designs, small quantities, any fabric | 1-100 pieces | No setup, moderate per-unit cost |
| Embroidery | Premium corporate wear, polos, hats, jackets | Any quantity | Digitizing fee, cost per stitch count |
Real Example
"We wanted 15 shirts with a full-color photo design. The screen printer quoted $850 because of setup fees for all the colors. We switched to DTF printing and paid $285 total—same quality, way cheaper for small runs." — Event Organizer, Vancouver
How to Avoid It
The Solution
- For orders under 24 pieces with full-color designs, choose DTF printing
- For bulk orders (24+) with simple 1-3 color designs, screen printing is most cost-effective
- For polo shirts, jackets, and premium corporate wear, embroidery looks most professional
- Check if your fabric is compatible—screen printing works best on cotton; DTF works on everything
- Get quotes for multiple methods to compare total costs, not just per-shirt pricing
- Ask the printer which method they recommend for your specific project
Pro Tip
Not sure which decoration method fits your needs? Read our comprehensive Screen Printing vs DTF vs Embroidery Guide for detailed comparisons with real pricing examples.
Ignoring Shrinkage When Sizing
The Risk
Your staff orders size Large. The shirts fit perfectly when they arrive. After the first wash, they've shrunk 1-2 inches in length and width. Now "Large" fits like a tight Medium. Half your team can't wear their uniforms comfortably.
Typical Cost Impact
20-40% of your order (the shirts that shrunk too much) needs replacement. For a 100-shirt order at $15/shirt, that's $300-600 in wasted inventory plus reorder costs.
Shrinkage by Fabric Type
| Fabric Type | Expected Shrinkage | Shrinks In... | Recommendation |
|---|---|---|---|
| 100% Cotton | 3-5% | Length more than width | Choose pre-shrunk; consider sizing up |
| 50/50 Cotton-Poly | 1-3% | Minimal in both directions | True to size usually works |
| 100% Polyester | <1% | Almost none | Maintains size well; order true to size |
| Tri-Blend | 2-4% | Moderate shrinkage | Pre-shrunk recommended; check brand specs |
Real Example
"We ordered 80 cotton t-shirts for our restaurant staff. After the first industrial wash, they all shrank significantly. Our taller employees' shirts became belly shirts. We had to reorder in larger sizes and eat the cost." — Restaurant Owner, Montreal
How to Avoid It
The Solution
- Always choose pre-shrunk garments when available (most quality brands offer this)
- For 100% cotton shirts, consider ordering one size up if recipients prefer roomier fits
- Provide washing instructions: cold water wash, tumble dry low minimizes shrinkage
- For workwear that gets washed frequently, cotton-polyester blends shrink less than 100% cotton
- Test-wash a sample shirt to see actual shrinkage before ordering large quantities
- Ask your printer which garment brands are pre-shrunk and how much residual shrinkage to expect
Pro Tip
All Gildan, Bella+Canvas, and Next Level shirts we stock are pre-shrunk. We recommend washing in cold water and tumble dry low to minimize any residual shrinkage (typically less than 2% after pre-shrinking). Learn more in our T-Shirt Blank Selection Guide.
Wrong Size Distribution for Groups
The Risk
You guess at size distribution: 20% Small, 40% Medium, 30% Large, 10% XL. When distribution day arrives, you're short on XL and 2XL while drowning in unwanted Smalls and Mediums. People leave disappointed and shirts go to waste.
Typical Cost Impact
15-30% of inventory becomes dead stock (wrong sizes). Rush reorder for missing sizes adds 50-100% cost premium. Total waste: $300-900 on a typical 100-shirt order.
Typical Size Distribution Patterns
| Group Type | S | M | L | XL | 2XL | 3XL+ |
|---|---|---|---|---|---|---|
| Mixed Adults (General) | 10% | 30% | 35% | 20% | 5% | 0% |
| Corporate (40+ avg age) | 5% | 25% | 35% | 25% | 8% | 2% |
| College/University | 15% | 35% | 30% | 15% | 5% | 0% |
| Trades/Labor | 5% | 20% | 35% | 30% | 10% | 0% |
| Women's Group | 20% | 35% | 30% | 12% | 3% | 0% |
Real Example
"I ordered 50 shirts for our team using 'standard' distribution. We ran out of XL and 2XL immediately, and had 12 Smalls left over. I had to rush-order more XL/2XL at double the price while the Smalls sit in a box unused." — HR Manager, Edmonton
How to Avoid It
The Solution
- Always collect actual size preferences from recipients—never guess distribution
- Use a simple Google Form or email survey to gather sizes before ordering
- Include a size chart with measurements so people can choose accurately
- Order 5-10% extra in popular sizes (typically M, L, XL) as buffer stock
- For events where sizes aren't collectible, use proven distributions for your demographic
- If mixing unisex and women's fits, be clear which style people are choosing
Pro Tip
We provide detailed size charts for every garment style we carry. Send us your size survey results and we'll review for any red flags (e.g., everyone chose Small—probably didn't check measurements). We'd rather get it right than deal with rushed reorders.
Choosing Based on Price Alone
The Risk
You find a printer offering t-shirts at $8 each when everyone else charges $12-15. You order 100 shirts to save $400-700. The shirts arrive paper-thin, colors fade after one wash, and prints crack and peel within a month. Nobody wears them.
Typical Cost Impact
$800-1,200 wasted on unusable shirts, plus $1,200-1,500 to reorder from a quality printer. Total loss: $2,000-2,700. The "savings" cost you 2-3x more than choosing quality from the start.
Hidden Costs of Cheap Apparel
Ultra-low pricing usually means cutting corners somewhere. Here's what you're actually getting:
- Thin, poor-quality blanks: 3.5 oz or lighter shirts that feel flimsy and shrink excessively
- Low-grade inks: Prints that crack, fade, or peel after a few washes
- Inconsistent sizing: The same "Large" varies wildly between different production runs
- Terrible customer service: No support when things go wrong; no reprints for errors
- Offshore production: Long lead times, customs delays, no recourse for quality issues
- Damaged brand reputation: Recipients associate your brand with cheap, low-quality merch
Real Example
"We chose the cheapest quote for our company anniversary shirts—saved $600 on 120 shirts. They arrived late, felt like paper, and the print started cracking after the first wash. We looked cheap in front of our employees. Ended up ordering from T-Shirt Elephant and paying more to get it done right." — Business Owner, Halifax
How to Avoid It
The Solution
- Focus on value, not just lowest price—what are you actually getting for your money?
- Ask what garment brands are used (Gildan, Bella+Canvas, etc.) and verify they're quality
- Request samples to evaluate actual quality before ordering large quantities
- Check reviews and ask for references from similar-sized orders
- Get detailed quotes breaking down garment cost vs printing cost vs setup fees
- Choose mid-tier quality at minimum—you don't need luxury, but avoid bottom-tier
- Remember: apparel that doesn't get worn is 100% wasted, regardless of price
Pro Tip
We use name-brand blanks (Gildan, Bella+Canvas, Next Level) and provide detailed quotes showing exactly what you're paying for. Our pricing is competitive because we buy at volume and run efficient operations—not because we cut corners on quality. Get a detailed quote from our Design Studio.
Missing the Timeline
The Risk
Your event is in 10 days. You place the order and expect the shirts to arrive in time. You didn't account for 2-3 days for artwork approval, 5-7 days for production, and 3-5 days for shipping. The shirts arrive 2 days after your event.
Typical Cost Impact
Rush production fees ($100-300), expedited shipping ($150-400), or complete order cancellation with 20-50% restocking fee. Total unexpected cost: $250-700 or total loss if too late.
Realistic Custom Apparel Timeline
| Phase | Standard Time | Rush Available? | Notes |
|---|---|---|---|
| Artwork Prep | 1-3 days | Same day (fee) | Depends on file quality and revisions needed |
| Proof Approval | 1-2 days | N/A | Waiting for customer to review and approve |
| Production | 5-7 days | 24-48 hrs (fee) | Varies by decoration method and order size |
| Shipping (Canada) | 3-5 days | 1-2 days (fee) | Standard ground vs expedited courier |
| Total Timeline | 10-17 days | 3-5 days ($$) | Always add 2-3 days buffer for safety |
Real Example
"We ordered jerseys 8 days before our tournament, thinking that was plenty of time. After artwork revisions and production, they wouldn't arrive until 2 days after the event. We paid $450 in rush fees and expedited shipping just to get them on time. Lesson learned—order 3 weeks ahead minimum." — Tournament Organizer, Winnipeg
How to Avoid It
The Solution
- Plan for 2-3 weeks from initial order to delivery for standard orders
- Add extra buffer time for orders over 200 pieces or complex designs
- Submit artwork early and respond quickly to proof requests to avoid delays
- Communicate your deadline upfront—printers can advise if it's realistic
- Build in 3-5 days of buffer in case of production or shipping delays
- If you need rush service, ask upfront about fees and realistic timelines
- For annual events, order 4-6 weeks ahead to avoid any stress
Pro Tip
We offer rush production (24-48 hours) for an additional fee when timeline permits. However, ordering 2-3 weeks ahead saves money and stress. Use our Design Studio to submit artwork early, and we'll provide an accurate production timeline based on your specific order.
Not Checking Return/Reprint Policies
The Risk
The shirts arrive with a printing error—your logo is crooked on 30% of the order. You contact the printer expecting a free reprint. They point to the fine print: "All sales final. No returns on custom orders." You're stuck with defective merchandise.
Typical Cost Impact
30-100% of order value depending on severity of error and printer policies. For a $1,200 order, you could lose $360-1,200 with no recourse if policies aren't clear upfront.
What Good Quality Guarantees Cover
- Printing defects: Crooked prints, misprints, ink smudges, incorrect colors
- Garment defects: Holes, stains, incorrect colors, manufacturing flaws
- Wrong items: Incorrect sizes, quantities, or styles shipped
- Production errors: Mistakes made by the printer during production
What Quality Guarantees Usually DON'T Cover
- Customer-supplied artwork errors: If you approved the proof and there's a typo in your artwork
- Subjective quality complaints: "I don't like how it looks" after approving the design
- Size/fit issues: If someone ordered the wrong size based on the size chart provided
- Change of mind: Deciding you want a different color or style after production starts
- Normal wear and tear: Fading or cracking after 50+ washes is expected, not a defect
Real Example
"We ordered 100 hoodies and 20 arrived with the logo printed 2 inches off-center. The printer had no quality guarantee and refused to reprint. We lost $380 on unusable inventory. Now I always ask about guarantees and get it in writing before ordering." — Non-Profit Director, Ottawa
How to Avoid It
The Solution
- Ask about quality guarantees before ordering—what's covered and what's not
- Get the reprint/refund policy in writing (email confirmation is fine)
- Understand the process: how do you report issues? What's the timeline for reprints?
- Clarify who pays for shipping on defective items (should be the printer)
- Review proofs carefully—once approved, customer errors usually aren't covered
- Take photos immediately if you receive defective items and report within 48 hours
- Choose printers with clear, customer-friendly guarantee policies
Pro Tip
T-Shirt Elephant guarantees our work 100%. If there's a production error or defective garment, we reprint at no charge. We cover shipping both ways for our mistakes. We want you to be completely satisfied—happy customers become repeat customers. Read our full Quality Guarantee.
Forgetting Care Instructions
The Risk
You distribute 100 custom t-shirts to your team. Nobody includes washing instructions. People wash in hot water and high heat dry. Within 2-3 washes, prints are cracking, colors are fading, and shirts have shrunk significantly. Your team blames poor quality.
Typical Cost Impact
Damaged brand reputation ("they gave us cheap shirts"), complaints and negativity, and potential reorder costs ($800-1,500 for 100 shirts) if you feel obligated to replace prematurely worn items.
Proper Care Instructions by Decoration Method
| Method | Washing | Drying | Special Notes |
|---|---|---|---|
| Screen Printing | Cold water, inside-out | Tumble dry low or hang dry | Avoid ironing directly on print |
| DTF Printing | Cold water, inside-out | Tumble dry low or hang dry | No bleach; wait 24hrs before first wash |
| Embroidery | Warm water okay | Any heat level | Very durable; minimal special care needed |
Real Example
"We gave our volunteers custom event shirts. Nobody mentioned they should wash inside-out in cold water. Everyone threw them in hot wash/high heat. After one wash, the prints looked terrible. People thought we bought cheap shirts, but it was just improper care. Now we include a care card with every order." — Event Coordinator, Saskatoon
How to Avoid It
The Solution
- Include a care instruction card with every shirt or package
- Send a follow-up email with washing instructions to all recipients
- For retail orders, attach care tags to garments
- Educate your team/customers: proper care extends garment life by 2-3x
- Create simple graphics showing proper care (inside-out, cold water, low heat)
- For workwear, train staff on proper laundering during onboarding
- Ask your printer for recommended care instructions specific to your decoration method
Pro Tip
We provide care instruction sheets with every order at no charge. For larger orders, we can print custom care tags with your branding. Proper care keeps your custom apparel looking great for years—and keeps your brand looking professional. Contact us for printable care instruction templates.
Not Keeping Reorder Records
The Risk
Six months later, you need to reorder the same shirts for new staff. You can't remember the exact garment style, color name, or print specifications. The reorder doesn't match your existing inventory. Now you have two different shades of "navy" and slightly different logo sizes.
Typical Cost Impact
Time wasted tracking down details ($100-200 in labor), potential artwork recreation fees ($50-150), and inconsistent branding across your team. Total inefficiency cost: $150-350 per reorder.
Essential Information to Save
- Exact garment details: Brand (Gildan), style number (5000), color name AND code (Navy #169)
- Artwork files: Final approved print-ready files in original format (AI, EPS, PNG)
- Print specifications: Size (12"W x 8"H), placement (center chest, 3" from collar), colors (PMS 286 Blue)
- Decoration method: Screen printing 2-color, DTF full-color, embroidery with stitch count
- Size distribution: How many of each size worked for your group
- Order confirmation & invoice: Complete paper trail for reference
- Supplier contact: Who you ordered from, account number, sales rep name
Real Example
"We ordered staff polos 18 months ago. When we needed more for new hires, we couldn't find the original order details. Reordered 'navy polos' but the blue was completely different. Our staff looked mismatched. Had to reorder the whole set in the new color. Saved all details this time in a shared drive." — Office Manager, Surrey
How to Avoid It
The Solution
- Create a dedicated folder (digital or physical) for each apparel order
- Save all email confirmations, invoices, and proofs in this folder
- Keep original artwork files with clear naming (CompanyName_Logo_2025.ai)
- Take photos of the actual finished products for visual reference
- Document size distribution results—what worked, what didn't
- Use a simple spreadsheet or note with all key details for quick reference
- Store information in a shared location so multiple team members can access it
Pro Tip
T-Shirt Elephant keeps your artwork files on record for 2 years and your order history indefinitely in your account. Reordering is simple—we have all your details saved. Create a free account in our Design Studio and your order history is always accessible.
Your Printable First-Time Buyer's Checklist
Print this checklist and check off each item before placing your custom apparel order
□ Order Samples
Request blank or printed samples to verify quality, color, and fit
□ Check Artwork Resolution
Ensure 300 DPI or vector files—no web images or screenshots
□ Select Right Decoration Method
Match method to quantity, design, and fabric type
□ Account for Shrinkage
Choose pre-shrunk garments; consider sizing up for 100% cotton
□ Collect Actual Sizes
Survey recipients for sizes—never guess distribution
□ Compare Total Value
Evaluate quality and service, not just lowest price
□ Plan 2-3 Week Timeline
Allow time for artwork, production, and shipping with buffer
□ Review Quality Guarantee
Understand what's covered and the reprint process
□ Include Care Instructions
Provide washing guidelines to extend apparel life
□ Save All Order Details
Keep files, specs, and confirmations for easy reordering
Frequently Asked Questions
Should I order sample t-shirts before placing a large order?
Absolutely! Ordering samples is the best way to verify fabric quality, color accuracy, and fit before committing to hundreds of shirts. Most printers offer blank samples or printed samples at low cost. This $20-50 investment can save you thousands by preventing mistakes on large orders.
What resolution should my artwork be for printing?
For best results, use 300 DPI (dots per inch) at actual print size. Vector files (AI, EPS, PDF) are ideal for screen printing and embroidery as they scale without quality loss. For DTF printing, high-resolution PNG files work well. Avoid screenshots and web images—they're typically only 72 DPI and will print blurry.
How do I choose between screen printing, DTF, and embroidery?
Screen printing is most cost-effective for orders of 24+ pieces with simple designs in 1-3 colors. DTF works for any quantity and prints full-color designs on any fabric. Embroidery provides the most premium, durable finish for logos on polo shirts and corporate wear. Your choice depends on quantity, design complexity, fabric type, and budget.
How much do t-shirts shrink after washing?
100% cotton t-shirts typically shrink 3-5% after the first wash, mostly in length. Cotton-polyester blends shrink less (1-3%), and 100% polyester shrinks minimally. Always choose pre-shrunk garments and consider ordering one size up for 100% cotton if you prefer a looser fit. Wash in cold water and tumble dry low to minimize shrinkage.
What is the typical size breakdown for group orders?
A common distribution for mixed adult groups is: 10% Small, 30% Medium, 35% Large, 20% XL, 5% 2XL. For corporate settings skewing older, add more XL/2XL. For younger audiences, add more S/M. Always collect actual size preferences rather than guessing—people's preferred fit varies significantly.
Why shouldn't I choose the cheapest custom t-shirt option?
The cheapest option often uses thin, poor-quality blanks that fade and shrink excessively. Low-quality printing cracks and peels within a few washes. Hidden costs include re-orders due to quality issues, disappointed recipients, and damaged brand reputation. Investing in mid-tier quality ensures your apparel actually gets worn and represents your organization well.
How long does custom apparel typically take to produce?
Standard production takes 5-7 business days after artwork approval, plus shipping time (3-5 days across Canada). For orders over 200 pieces or complex designs, add 2-3 extra days. Rush orders (24-48 hours) are available for additional fees. Always order at least 2-3 weeks before you need the apparel to avoid rush charges.
What should I look for in a printer's quality guarantee?
Look for guarantees covering printing errors, defective garments, and color accuracy. Reputable printers will reprint at no charge for their mistakes. Check if the guarantee covers artwork you supplied (usually not) versus production errors (should be covered). Ask about the process for reporting issues and turnaround time for reprints.
Do I need to provide washing instructions with custom apparel?
Yes! Different decoration methods require different care. Screen printing and DTF last longest when washed inside-out in cold water. Embroidery is very durable but avoid high heat. For team uniforms or customer orders, include a care card or email with washing instructions to ensure your custom apparel stays looking great for years.
What information should I save for future reorders?
Save: exact garment style and color names/codes, artwork files, print specifications (colors, sizes, placements), and size distribution. Create a folder with your order confirmation, proof approvals, and final invoice. This makes reordering seamless and ensures consistency across multiple orders. Most printers keep files on record for 1-2 years.
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