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.
1. Using Low-Resolution Artwork
This is by far the most common mistake. 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.
2. Designing in RGB Instead of CMYK
Screens display colours using RGB, while printing uses CMYK inks. Colours that pop on screen don't always translate the same way in print. Design in CMYK colour mode where possible and use Pantone (PMS) colours for brand-critical designs.
3. Forgetting About Transparency
If your file has a white background instead of transparency, that background will print too. Use transparent PNG files and remove background layers before exporting.
4. Placing Fine Details Too Small
Tiny text and ultra-thin lines might look great on screen, but fabric isn't as forgiving. Text should be at least 5-6 pt at print size and line weights should be no thinner than 1-1.5 pt.
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.
6. Not Allowing for Print Size and Placement
Designing without knowing where and how big your print will be is risky. Ask for a print size guide and specify placement clearly.
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.
8. Using the Wrong File Type
Best file types: AI/EPS/PDF (vector), PNG (high-resolution, transparent), PSD (with layers intact). Avoid Word documents, PowerPoint files, and Canva exports without print settings checked.
9. Not Accounting for Fabric and Print Method
Different fabrics behave differently. DTG works best on 100% cotton. Polyester requires special inks. Choose your garment first, then design around it.
10. Skipping Professional Artwork Checks
At Halo Print Co, we include artwork checks with every order to catch issues before they become expensive mistakes.