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Custom T-shirt printing is a powerful way to promote your brand, unite teams, and create merchandise people actually want to wear. But when things go wrong, the result can be wasted stock, missed deadlines, and disappointed customers.
T-Shirt Plus sees the same issues come up time and time again. The good news? Most of them are avoidable with the right process, materials, and supplier.
Below are the most common custom t-shirt printing problems and how to fix them.
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Poor Print Quality
Poor print quality is one of the most common and frustrating issues in custom T-shirt printing. The final print may appear blurry, pixelated, uneven, faded, or cracked. In some cases, the design might look acceptable on delivery but quickly deteriorates after the first wash. This not only affects the look of the garment but also reflects badly on the brand wearing it.
Why does it happen:
This issue is usually caused by low-resolution artwork that isn’t suitable for printing, incorrect printing methods being used for the design, or substandard inks and equipment. Artwork created for digital use (such as social media images or screenshots) often lacks the resolution required for physical printing. In addition, budget printing setups may not apply ink evenly or cure it correctly.
How to fix it:
Always start with high-resolution, print-ready artwork. Vector files (such as AI, EPS, or PDF) are ideal because they scale without losing quality. Choose the correct printing method for the design — screen printing works best for bold, simple logos, while DTG is better suited to detailed or photographic artwork. Work with a professional printer that uses commercial-grade equipment, quality inks, and strict quality control processes.
Colours Don’t Match Expectations
The colours on the printed T-shirt look noticeably different from what was approved on screen. Whites may appear dull, bright colours may look muted, or brand colours may shift enough to be recognisable as “off”.
Why does it happen:
Screens display colours using RGB light, while printing uses CMYK inks or spot colours. This means colours can never look exactly the same on fabric as they do on a screen. Fabric colour and fabric type also affect how ink sits and absorbs, changing the final appearance of the print.
How to fix it:
For brand-critical work, always request a physical colour proof or sample. Use Pantone (PMS) colours where consistency is essential, especially for logos. An experienced printer will adjust ink formulations based on garment colour and fabric type to get the closest possible match.
Designs Printed in the Wrong Position or Size
Logos and designs appear too large, too small, off-centre, or awkwardly positioned on the garment. This can make an otherwise good design look unprofessional or poorly planned.
Why does it happen:
This usually occurs when placement instructions are unclear or assumed. Without a confirmed visual reference, printers may rely on standard positioning that doesn’t suit every design or garment style.
How to fix it:
Always approve a detailed mock-up that shows exact placement, size, and orientation on the garment. Measurements should be clearly defined, not just described. A professional printer will confirm placement details before production begins and flag any potential issues early.
The Print Doesn’t Last
After a few washes, the print begins to crack, peel, or fade. This reduces the lifespan of the garment and makes it unsuitable for uniforms, workwear, or resale.
Why does it happen:
Common causes include incorrect curing temperatures, low-quality inks, or using the wrong printing method for the garment fabric. Poor wash care can also contribute, but the root cause is usually in production.
How to fix it:
Use proven printing methods such as properly cured screen printing or high-quality DTG printing. Ensure garments are cured at the correct temperature and tested for durability. Follow recommended wash care instructions and work with a printer that prioritises longevity, not just appearance.
Wrong T-Shirt Fabric Choice
The T-shirt feels uncomfortable, shrinks after washing, traps heat, or simply doesn’t suit how it’s being used. This can lead to garments being worn less or not at all.
Why does it happen:
Fabric is often chosen based on price rather than purpose. Not all fabrics behave the same way when printed or worn, and cheaper options may compromise comfort and durability.
How to fix it:
Choose fabric based on the intended use. Cotton offers comfort and breathability, polyester blends provide durability and moisture-wicking, and heavier-weight fabrics are ideal for workwear. A knowledgeable printer will help you select the right garment for your application.
Sizes and Fits Are Inconsistent
Customers or staff receive shirts that don’t fit as expected, resulting in dissatisfaction, returns, or unused stock.
Why does it happen:
Different brands and styles follow different sizing standards, even when labelled the same size. Unisex, slim-fit, and relaxed-fit garments all fit differently.
How to fix it:
Review size charts carefully and don’t assume sizing consistency across brands. Where possible, order samples before committing to bulk production. Stick with the same garment brand and style for repeat orders to maintain consistency.
Delays in Production or Delivery
Custom T-shirts arrive late, missing deadlines for events, promotions, staff onboarding, or product launches.
Why does it happen:
Delays are often caused by unclear timelines, last-minute artwork changes, supply chain issues, or printers overpromising on turnaround times.
How to fix it:
Plan ahead and confirm production and delivery timelines before placing the order. Avoid last-minute changes once production has started. Choosing a local Australian printer with in-house production and transparent lead times significantly reduces risk.
Hidden Costs and Budget Blowouts
The final invoice is higher than expected due to unexpected fees or charges.
Why does it happen:
Set-up fees, artwork adjustments, colour changes, or minimum order requirements may not be clearly explained upfront.
How to fix it:
Work with a printer that provides clear, upfront pricing and explains all costs before production begins. A detailed quote should outline set-up fees, printing costs, and any potential additional charges.
Artwork Isn’t Print-Ready
The supplied design cannot be printed as-is, causing delays or additional costs.
Why does it happen:
Artwork may be low resolution, missing fonts, saved in the wrong format, or not designed with printing in mind.
How to fix it:
Provide vector artwork wherever possible. If that’s not available, allow time for a professional artwork setup. Many experienced printers offer in-house design services to prepare artwork correctly before printing.
Choosing the Wrong Printing Method
The print may look fine initially but fails to perform well over time or doesn’t suit the garment or design.
Why does it happen:
A one-size-fits-all approach is applied without considering order volume, design complexity, or fabric type.
How to fix it:
Match the printing method to the job:
- Screen printing for bulk orders and bold, simple designs
- DTG printing for detailed, full-colour artwork
- Heat transfers for small runs, personalisation, or names and numbers
An experienced printer will assess your needs and recommend the most suitable method for quality, durability, and cost-effectiveness.
Most custom T-shirt printing problems come down to poor planning, unclear communication, or choosing the wrong supplier.
T-Shirt Plus focuses on quality control, clear approvals, and the right printing method for every job, so your custom apparel looks great, lasts longer, and delivers real value for your brand.
If you’re planning a custom T-shirt order and want it done right the first time, working with experienced professionals makes all the difference.
