T-Shirt Design Mistakes to Avoid Before You Print
Designing a custom t-shirt is exciting, whether it’s for your brand, event, merch drop, band, gym, or business. But one small design mistake can be the difference between a shirt you’re proud to wear and one that ends up at the back of the cupboard.
At Halo Print Co, we see incredible ideas come through every day, and we also see the same avoidable issues that can impact print quality, colour accuracy, and durability. The good news? Most of these mistakes are easy to fix before printing begins.
Here are the most common t-shirt design mistakes to avoid, and how to prepare your artwork properly for the best possible result.
1. Using Low-Resolution Artwork
This is by far the most common mistake.
If your design looks sharp on your phone but blurry on a computer screen, it’s almost guaranteed to print poorly. Low-resolution images can appear pixelated, fuzzy, or muddy once transferred onto fabric.
What to do instead:
Always use high-resolution files (300 DPI)
Vector formats like AI, EPS, or PDF are ideal
For raster images, PNG or PSD files at print size work best
Avoid screenshots, social media images, or artwork pulled from Google. They’re rarely print-ready.
2. Designing in RGB Instead of CMYK
Screens display colours using RGB, while printing uses CMYK inks. Colours that pop on screen (especially neons, bright blues, and vibrant greens) don’t always translate the same way in print.
Common issues:
Dull or muted colours
Unexpected colour shifts
Blacks printing grey or washed out
Best practice:
Design in CMYK colour mode where possible
Use Pantone (PMS) colours for brand-critical designs
Ask your printer for colour guidance if accuracy matters
At Halo Print Co, we always review colours before printing and flag anything that may not translate well.
3. Forgetting About Transparency
Transparent backgrounds are essential for clean prints — especially on coloured garments.
If your file has a white background instead of transparency, that background will print too (and it won’t look intentional).
Avoid this by:
Using transparent PNG files
Removing background layers before exporting
Avoiding JPEGs for final print files
This is especially important for logos, typography, and minimalist designs.
4. Placing Fine Details Too Small
Tiny text and ultra-thin lines might look great on screen, but fabric isn’t as forgiving.
During printing:
Small text can fill in
Thin lines can break or disappear
Intricate details may lose clarity
Our general rule:
Text should be at least 5–6 pt at print size
Line weights should be no thinner than 1–1.5 pt
Simplify details where possible
If your design relies on fine detail, DTG or DTF printing may be better than screen printing.
5. Ignoring Shirt Colour in the Design
Your design doesn’t exist in isolation — it sits on fabric.
A design that looks amazing on a white artboard can disappear on a black or coloured shirt if contrast isn’t considered.
Common mistakes:
Dark designs on dark garments
Light text on light shirts
No underbase for darker fabrics
Fix it by:
Testing your design on the actual shirt colour
Adding outlines or strokes where needed
Letting your printer handle underbases properly
We always recommend previewing artwork against the garment colour before final approval.
6. Not Allowing for Print Size and Placement
Designing without knowing where (and how big) your print will be is risky.
Front chest prints, centre chest prints, sleeve logos, back prints — all require different sizing and positioning.
Common issues:
Designs printed too large or too small
Logos placed too high or low
Back prints sitting awkwardly
Best approach:
Ask for a print size guide
Specify placement clearly (e.g. centre chest, left chest)
Trust your printer’s layout recommendations
At Halo Print Co, we’ll always mock up placement if there’s any doubt.
7. Overloading the Design With Too Many Colours
More colours don’t always mean a better shirt, especially for screen printing.
Each colour requires its own screen, which can:
Increase cost
Increase setup time
Increase the chance of registration issues
Consider:
Reducing colours where possible
Using halftones or gradients strategically
Choosing the right print method for complex designs
For small runs or photo-style artwork, DTG or DTF printing may be the better option.
8. Using the Wrong File Type
Sending the wrong file format can delay your order or compromise quality.
Best file types for printing:
AI / EPS / PDF (vector — best option)
PNG (high-resolution, transparent)
PSD (with layers intact)
Avoid:
Word documents
PowerPoint files
Canva exports without print settings checked
If you’re unsure, our team is always happy to review files before printing.
9. Not Accounting for Fabric and Print Method
Different fabrics behave differently.
What works on a cotton tee might not work on polyester, fleece, or performance wear.
Examples:
DTG works best on 100% cotton
Polyester requires special inks
Heavy ink coverage can feel stiff on lighter fabrics
Pro tip:
Choose your garment first, then design around it, not the other way around.
10. Skipping Professional Artwork Checks
Even experienced designers can miss things.
At Halo Print Co, we include artwork checks with every order to catch issues before they become expensive mistakes.
We’ll look for:
Resolution problems
Colour accuracy
Placement issues
Print suitability
This step alone saves our customers time, money, and frustration.
Final Thoughts: Design Smart, Print Better
Most t-shirt printing issues don’t come from bad ideas, they come from small technical oversights.
By avoiding these common t-shirt design mistakes and preparing your artwork correctly, you’ll get:
Cleaner prints
Better colour accuracy
Longer-lasting garments
A more professional final result
If you’re unsure whether your design is print-ready, send it through. Our team at Halo Print Co is always happy to review your artwork and recommend the best printing method for your project.
Ready to print? Place a quick order today, and let’s make your design look as good on fabric as it does in your head.
