How We Print Bulk Custom Apparel at Zooks: From Fabric to Finish
- zooksteam
- 3 days ago
- 4 min read
When apparel brands, startups, or corporates plan bulk apparel customization, one common challenge is choosing the right printing method. Each method has its strengths and limitations depending on fabric type, design complexity, durability needs, and budget. Selecting the wrong technique can lead to disappointing results, higher costs, or products that don’t last. At Zooks, we’ve worked with hundreds of bulk buyers across India, helping them navigate these choices with practical insights and hands-on experience.
This post explains four popular printing methods: Direct to Film (DTF), sublimation, embroidery, and screen printing. We’ll explore where each method works best, share real examples from bulk orders, and offer a simple comparison to help you decide what fits your project. By the end, you’ll understand how to match your apparel needs with the right printing process.
Direct to Film (DTF) Printing
DTF printing has gained popularity for bulk apparel customization because it offers vibrant colors and works well on various fabrics. The process involves printing designs on a special film, then transferring them to fabric using heat and adhesive powder.
Best for: Cotton, polyester, blends
Durability: Good wash resistance, lasts 20-30 washes if cared for properly
Cost: Moderate, suitable for medium to large orders
Use case: Complex, multicolor designs; sportswear; promotional t-shirts
For example, a startup ordering 500 cotton-polyester blend t-shirts for a product launch chose DTF to capture their colorful logo and intricate graphics. The prints stayed bright and intact after multiple washes, making it a cost-effective choice without compromising quality.
DTF works well on both light and dark fabrics, which adds to its versatility. The feel of the print is soft, and it doesn’t crack easily, making it comfortable for everyday wear.
Sublimation Printing
Sublimation uses heat to transfer dye directly into polyester fabric, creating vibrant, permanent designs that won’t peel or fade.
Best for: 100% polyester or polyester-rich fabrics
Durability: Excellent, colors last for the garment’s lifetime
Cost: Higher setup cost but economical for very large runs
Use case: Sports jerseys, all-over prints, fashion apparel
A corporate client ordered 1,000 polyester sports jerseys with full-coverage sublimation prints. The colors remained sharp even after intense use and washing, ideal for their team uniforms. Sublimation allows for detailed, full-bleed designs that cover the entire garment, which is impossible with other methods.
However, sublimation doesn’t work on cotton or dark fabrics, limiting its use to polyester blends or light-colored polyester.
Embroidery
Embroidery involves stitching thread into fabric to create logos or designs. It adds texture and a premium feel to apparel.
Best for: Cotton, polyester, denim, thicker fabrics
Durability: Very high, withstands frequent washing and wear
Cost: Higher per piece, especially for complex or large designs
Use case: Corporate uniforms, caps, premium merchandise
For example, a corporate bulk order of 300 polo shirts featured embroidered company logos on the chest and sleeves. The embroidery gave the shirts a professional look and lasted for years without fading or peeling, perfect for client-facing staff.
Embroidery is less suited for large, detailed images or photographic designs but excels at logos, monograms, and simple graphics.
Screen Printing
Screen printing is a traditional method where ink is pushed through a mesh stencil onto fabric. It’s cost-effective for large runs with fewer colors.
Best for: Cotton and cotton blends
Durability: Very good, especially with plastisol inks
Cost: Low per piece for large volumes, higher setup costs for multiple colors
Use case: T-shirts, promotional apparel, simple designs
A bulk order of 1,000 cotton t-shirts for a festival used screen printing with two colors. The prints were bold, durable, and affordable, making it ideal for budget-conscious buyers needing large quantities.
Screen printing works best with simple designs and fewer colors. It can produce a slightly raised texture and is less suited for photographic or gradient images.
Comparing Printing Methods
Printing Method | Best Fabric Types | Durability | Cost Efficiency | Ideal Use Cases |
DTF | Cotton, polyester blends | Good (20-30 washes) | Moderate | Multicolor designs, sportswear |
Sublimation | 100% polyester | Excellent | High setup, low per piece | Full-coverage prints, jerseys |
Embroidery | Cotton, polyester, denim | Very high | Higher per piece | Logos, corporate uniforms, premium wear |
Screen Printing | Cotton, cotton blends | Very good | Low per piece (large runs) | Simple designs, promotional t-shirts |
How We Help Brands Choose the Right Printing at Zooks
At Zooks, we understand that every bulk apparel customization project is unique. Our team works closely with brands to assess fabric choices, design complexity, budget, and intended use. We provide samples and mock-ups so clients can see and feel the print quality before committing to large orders.
For instance, a startup launching eco-friendly cotton tees wanted vibrant prints but had a limited budget. We recommended DTF printing for its balance of cost and quality. Another client needed premium embroidered polos for their sales team, so we focused on thread colors and stitch density to ensure durability and style.
Our experience with bulk orders across India means we can guide you through the pros and cons of each method, helping you avoid costly mistakes and get the best value.
👉 For bulk apparel inquiries or customized clothing production, connect with Zooks for professional guidance and reliable manufacturing.
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