Introduction
There are many ways to decorate products. From screen printing to sublimation to embroidery, each decorating process is unique. Even among the different processes there are specialty and trendy decorating options. There are rhinestones, applique, and specialty heat press transfers. Each of these specialty product decorations has its own market. For instance, rhinestones and glitter are extremely popular with younger girls and women, especially cheerleaders and dancers. Children are typically fond of specialty transfers like glow-in-the-dark, color-changing, and puff.
Screen printing is the cheapest method of apparel decoration, while also providing one of the most vibrant and opaque prints of any printing process. When screen printing, a printer drags ink across a screen, which has a design burned into it, over top of a shirt. This forces ink onto the garment in the shape of whatever design was burned into the screen. Most of the print costs are derived from the setup process rather than the printing itself. Artwork requirements can be an impediment to completing a print job and a screen must be prepared for each color in the design, because each color must be printed separately. It can also be very expensive to create full color prints or even prints with over four colors. The biggest issue with screen printing, though, is that it requires a minimum of 12 pieces for an order. It is simply not economical to go to all the effort of preparing artwork, creating screens, and printing in order to make a single garment. For bulk orders, however, screen printing is the best option by far. A practiced screen printer with an automatic screen print machine can print upwards of 500 garments in an hour.
Screenprint transfer printing is similar to direct screen-printing, however, instead of printing directly onto a garment, special ink is printed onto a release paper, which can then be heat-applied onto a variety of products. Screen print transfers are extremely versatile. They can be printed onto cotton, polyester, and blended garments, as well as bags, towels, hats, and other accessory products. Artwork for screen print transfers can be “ganged” in order to reduce costs. Ganging artwork means that several designs can be printed onto a single sheet of transfer paper, which lowers the cost of the transfers. There is also a lower equipment cost than other product decoration methods, and the print time is much quicker. With screen print transfers, you do not have to hold printed inventory. Rather, you can print on-demand, which saves money and prevents you from being stuck with printed inventory that you may or may not sell. However, there is a larger upfront cost in the form of the transfers, which you are dependent upon to be able to print.
Direct-To-Garment (DTG) printers operate much like an inkjet printer, except they print onto garments instead of paper. DTG printers are capable of printing on any color and require no minimum amount of prints to order due to the speed with which you can change the design to be printed. DTG printing is primarily used for printing onto 100% cotton garments, however certain blends do work as long as they are least 50% cotton. One of the major advantages to printing DTG is the fact that the artwork does not require special formatting like screen printing and embroidery. DTG printers are capable of full-color, photo quality printing. All these qualities make DTG the go-to printing method for small-to-medium online print shops, and even smaller printing stores. DTG printing, like every decoration process, is not without its drawbacks, though. Obviously the available product line is limited to cotton products and certain blends. In addition to a limited product line, the cost of DTG ink is quite high, especially when compared to screen printing. Also, while DTG printers are fully capable of printing on darker garments, there are many possible complications with them, like bleeding or banding.
Embroidery is the oldest product decoration method that is still common today. Embroidery involves a machine stitching designs into fabric with a needle and thread. Current embroidery machines are capable of stitching designs with up to 15 colors. Logos and monograms are the most common types of embroidery, as the majority of embroidered designs are rather small. In order to operate an embroidery machine, you will also need a computer with which to prepare artwork and send print-ready files to the machine. Embroidery has a high perceived value when compared to alternative product decoration methods, but embroidery machines are expensive and require regular maintenance. Embroidery machines can easily stitch most cotton garments, polos, bags, and jackets. Softer and more flexible fabrics, like polyester, will not stitch well because the sewing process will pull the fabric, creating a wavy look on the finished product. This is referred to as puckering.
Sublimation printing is primarily used for gift products and awards, though white 100% polyester garments can be printed as well. However, since that is such a unique printable garment, it is uncommon to print apparel using the sublimation method. The sublimation process is very simple, and like the screen print transfer process. A dye-sublimation printer will print a mirrored image of the final print onto special paper with dye-sublimation ink, which will sublimate when pressed onto the product at a high temperature. Sublimation printers are capable of full-color, photo quality prints. Each different product that can be sublimation-printed will require different time, temperature, and pressure settings in order to create the optimal print. This is important to remember considering that there are a vast amount of products that can be printed, from coffee mugs and plaques to coasters and puzzles.
Rhinestones are small pieces of glass or acrylic that are meant to imitate diamonds. They can be used in place of ink to create a design or even to outline one. Rhinestones can be applied to a variety of products, from pants and shirts to bags and hats. Rhinestone designs are typically created using a setting machine that places the stones onto a transfer backing that then can be heat applied using a heat press.
Applique is a piece of fabric that is sewn or pressed onto another fabric to create a new design. Applique is a common decoration method for sweatshirts and jackets (think letterman jackets). Applique is first cut using a laser to cut the design instead of a metal blade so that the edges do not fray. The applique then must be sewn onto the product using an embroidery machine.
A newer decoration method is laser etching, which involves the design being burned into a fabric with a laser, creating an image that is just a few shades darker than the garment itself. Laser etching works best on medium-colored garments, as the resulting image will struggle to stand out from darker garments and whites. This method is most commonly used for one-color corporate logos or names.
Another decoration method worth mentioning here is cutting & sewing. In this process, the fabric is sublimation printed before being cut and sewn into a garment. Cutting & sewing gives the product decorator the ability to decorate an entire garment rather than just one or two printable areas. Many polyester, moisture-wicking, and other sports apparel products are now made this way. Many soccer, baseball, wrestling, cycling, track, and other sports are products are first printed using sublimation printers and then each garment is sewn together. While this decoration method offers great customization options it is typically expensive, has a long turnaround time, and is best used for larger orders rather than single garments.
When it comes to specialty screen printing inks / heat transfers, there are many options. Glow in the dark transfers are fun for children of all ages. Puff transfers add a 3D aspect to a design and really stand out. Glitter, well, speaks for itself. Glitter transfers are great for printing cheerleading and other female-targeted products. Perhaps the coolest product decoration method of all is the color-changing transfer. When indoors and deprived of UV light, these designs seem black and white. However, when exposed to sunlight (and therefore UV rays), the colors in the design can be seen. It is a neat effect to witness, and the colors are as vibrant as a typical transfer in the sunlight.
Closing
Clearly there are a wide variety of decoration options available to anyone hoping to start a new product decoration business. The processes offered to customers should be dictated by the market, and the needs that a new business could fulfill. If a new decoration shop could become a one-stop shop for customers’ product decoration needs, it is possible to utilize most, if not all, these processes either in house or by outsourcing. So, if you are looking to start a product decoration business, investigate your market and do your best beforehand to figure out what equipment you will need in order to offer the best combination of products to your customers.
