Custom Printing FAQ — Screen Printing, Embroidery & DTF Questions | The Fan Gear Guy

Question 1

What file format should I send for my artwork?

Accepted Answer

Vector files (AI, EPS, PDF) are ideal for screen printing because they scale without losing quality. High-resolution PNGs (300 dpi or higher) at print size also work well. If you only have a low-res file, our design team can redraw it for you.

Question 2

How many colors can I print?

Accepted Answer

We support up to 8 spot colors per design. Each color requires a separate screen, so designs with fewer colors are generally more cost-effective. Full-color photographic prints are better suited to DTF printing.

Question 3

What is the turnaround time?

Accepted Answer

Standard orders ship in 5–7 business days after art approval. Rush production (2–3 business days) is available for an additional fee. Contact us before placing your order if you have a hard deadline.

Question 4

Can I print on dark garments?

Accepted Answer

Yes. We use an underbase white ink layer on dark fabrics to keep colors bright and accurate. This adds one screen to the job but ensures the final print looks exactly as intended.

Question 5

Do you offer discharge or water-based printing?

Accepted Answer

Yes. Water-based and discharge inks are available for a softer hand feel and a more vintage look. These work best on 100% cotton garments and lighter colors.

Question 6

What garment brands do you print on?

Accepted Answer

We stock Gildan, Bella+Canvas, Next Level, and Port & Company. You can also supply your own blanks — just contact us first so we can confirm they are print-ready.

Question 7

What is digitizing and do I need to pay for it?

Accepted Answer

Digitizing converts your artwork into a stitch file our embroidery machines can read. There is a one-time digitizing fee per design. Once digitized, your file is saved for future orders at no additional charge.

Question 8

What file format works best for embroidery?

Accepted Answer

Vector files (AI, EPS, PDF) give us the cleanest starting point. High-resolution PNGs work too. Avoid low-res JPEGs — fine details and thin lines may not translate well to stitches.

Question 9

Can you embroider on hats and structured caps?

Accepted Answer

Yes. We embroider on structured caps, beanies, visors, and most headwear. Flat embroidery works on the front panels; 3D puff embroidery is also available for a raised, bold look.

Question 10

How many thread colors can I use?

Accepted Answer

Up to 15 thread colors per design. More colors add stitching time but do not increase the per-piece cost significantly. We will match your brand colors as closely as possible using Madeira or Isacord thread charts.

Question 11

Is embroidery suitable for very small or detailed logos?

Accepted Answer

Embroidery has a minimum stitch size, so very fine details or thin text under 0.25 inches tall may not reproduce cleanly. Our digitizing team will flag any issues and suggest adjustments before production.

Question 12

What is the turnaround time for embroidery orders?

Accepted Answer

Standard turnaround is 7–10 business days after art approval and digitizing sign-off. Rush options are available — contact us with your deadline.

Question 13

What is DTF printing and how does it work?

Accepted Answer

DTF (Direct-to-Film) printing transfers a full-color design onto a special film, which is then heat-pressed onto the garment. It produces vibrant, photo-quality prints with no color limits and works on virtually any fabric.

Question 14

What fabrics can DTF be applied to?

Accepted Answer

DTF works on cotton, polyester, blends, nylon, leather, and more. Unlike screen printing, it does not require a 100% cotton garment, making it ideal for performance wear and mixed-fabric items.

Question 15

How does DTF compare to screen printing?

Accepted Answer

DTF has no color limits and no minimum order quantity, making it great for small runs and complex artwork. Screen printing is more cost-effective for large quantities of simple, spot-color designs.

Question 16

What file format should I send?

Accepted Answer

PNG files with a transparent background are ideal for DTF. We also accept AI, EPS, and PDF. Minimum 300 dpi at print size for the best results.

Question 17

How durable is a DTF print?

Accepted Answer

DTF prints are highly durable and wash-resistant when cared for properly. Turn garments inside out, wash in cold water, and avoid high-heat drying to maximize print life.

Question 18

Can DTF print white ink on dark garments?

Accepted Answer

Yes — this is one of DTF's biggest advantages. White ink is included in every transfer, so colors pop on black, navy, and other dark fabrics without a separate underbase step.

Question 19

What is the difference between embroidered and woven patches?

Accepted Answer

Embroidered patches use raised thread stitching and are great for bold, simple designs. Woven patches use thinner threads on a loom, allowing finer detail and smaller text. PVC patches are molded rubber — durable, waterproof, and great for a 3D look.

Question 20

What are PVC patches made of?

Accepted Answer

PVC patches are made from soft, flexible polyvinyl chloride rubber. They are waterproof, UV-resistant, and extremely durable — popular for tactical gear, bags, and outdoor apparel.

Question 21

What attachment options are available?

Accepted Answer

We offer iron-on backing, sew-on (no backing), Velcro (hook side attached), and adhesive backing. Let us know your preference when ordering.

Question 22

What file format should I send for my patch design?

Accepted Answer

Vector files (AI, EPS, PDF) are preferred. High-resolution PNGs at 300 dpi also work. Include a color callout so we can match thread or PVC colors accurately.

Question 23

What is the turnaround time for custom patches?

Accepted Answer

Standard production is 10–14 business days after art approval, which includes a digital proof for your sign-off. Rush options may be available — contact us with your deadline.

Question 24

Can I see a proof before production starts?

Accepted Answer

Yes — every patch order includes a digital proof for your approval before we go to production. No patches are made until you sign off on the design.

Question 25

What blank brands do you carry?

Accepted Answer

We stock Gildan, Bella+Canvas, Next Level, Port & Company, and select styles from Champion and Independent Trading Co. Availability varies by style and color — contact us for current stock.

Question 26

Do you carry extended sizes?

Accepted Answer

Yes. Most styles are available from XS through 5XL. Extended sizing availability varies by brand and color — contact us with your specific size needs and we will confirm stock before you order.

Question 27

Can I order blanks without printing?

Accepted Answer

Yes. We sell blank apparel wholesale with no decoration required. Minimum order quantities may apply depending on the brand and style.

Question 28

Are the blanks pre-washed?

Accepted Answer

Most blanks are not pre-washed. We recommend washing before wearing, especially for 100% cotton styles that may shrink slightly on first wash.

Question 29

How quickly do blanks ship?

Accepted Answer

In-stock blanks typically ship within 2–3 business days. Larger orders or less common styles may require additional lead time.

Question 30

Can I mix styles, colors, and sizes in one order?

Accepted Answer

Yes. You can mix styles, colors, and sizes within a single order. Pricing is based on the total quantity ordered, so mixing does not affect your per-piece cost.

Frequently Asked Questions

Screen Printing

Embroidery

DTF Printing

Custom Patches

Blank Apparel

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