The Most Common Custom Apparel Design Mistakes
Published by: Siobhan Ingram
Date: 05-06-2025
It appears straightforward—select a tee, insert a logo, print it. But if you've ever taken the final product in your hand and thought, "Huh… that did not look quite as I imagined," fear not, you're not the only one. There are a few design mistakes that catch up to even the most well-intentioned groups.
Whether you're having shirts printed for your business, a team, or a fundraiser, these are the most common design errors to steer clear of—so your personalized tee really does look as good as it can.
Complicating the Design Too Much
We get it—on your mind are the logo, the slogan, the website, maybe a graphic, maybe a sponsor or two. And when too many of these are added to one design, well, it gets too crowded and hard to read.
The best merch? It's usually plain, bold, and easy to see from a distance. Let your main message take center stage and don't hesitate to leave some room.
Incorrect use of Low-Resolution or Incorrect File Types
This is a doozy. If you're submitting a squishy logo or screen shot of a design, your printer can only do the best it can. For clean, sharp results—especially with screen printing or embroidery—you'll need high-res or vector files (.AI, .EPS, or high-quality .PDFs).
If you don't know what type of file you have, ask your designer—or your print partner. They'll thank you.
Not Thinking About Fabric Color
A white logo on a light gray shirt? A navy design on a black shirt? Some combinations just don't work. Contrast is key. Without it, your art becomes invisible.
Before you go to print, always take a look at a mockup of your design on the actual color of the garment. Better yet, test it out on different swatches of fabric if you're printing a large quantity.
Forgetting About Real-World Fit & Size
A design that looks amazing on a screen might feel totally different when it's printed on a size small or stretched over a 2XL. If your artwork is very tall or way too detailed, it simply might not work well over all shirt sizes.
Design with balance and placement in mind—and, if in doubt, have your print team resize it wisely over sizes.
Ignorance of Print Method Limitations
Embroidery, screen printing, DTG—they all have different strengths. A super detailed photo might work digitally but look messy in thread. A design with seven ink colors could drive up screen printing costs fast.
Before finalizing your design, make sure it fits the production method you’re using. This saves time, money, and avoids unwanted surprises.
Custom apparel should feel intentional—not like an afterthought. By keeping your design simple, clear, and print-friendly, you’ll create something people actually want to wear. And when that happens, your merch goes from “just another shirt” to something worth repping.