First Custom Shirt Order Mistakes and How to Avoid Them

Published November 9, 2026. Last updated November 9, 2026.

The biggest custom shirt order mistakes are guessing sizes, sending a low-resolution logo, choosing a blank that does not fit the use, ordering too close to the event and approving the proof without checking it. Each one is easy to avoid. Quokka Prints walks first-time buyers through every step, starting with free custom artwork within 24 hours.

What are the most common mistakes on a first custom shirt order?

The most common mistakes on a first custom shirt order fall into five groups: sizes, artwork, garment choice, timing and proof approval. Almost every disappointing order traces back to one of them, and none of them has anything to do with bad luck. A PTA chair, coach or office manager who knows where orders usually go wrong can sidestep all five with a little planning.

• Sizes: guessing the size split instead of asking people, which leaves a pile of extra larges and nobody in a small.
• Artwork: sending a tiny logo pulled from a website or a social media post, which can print soft or blurry.
• Garment: picking a shirt for its look on a screen rather than how it will be worn, washed and handed out.
• Timing: starting the order a few days before the event and hoping production can squeeze it in.
• Proof: approving the mockup in a hurry and missing a typo, a wrong color or a misplaced logo.

The rest of this guide covers each mistake in turn, with a practical fix you can use on your next order with Quokka Prints, whether it is spirit wear, a race shirt, camp tees or staff apparel.

Why does guessing sizes cause problems on a custom shirt order?

Guessing sizes causes problems because custom shirts are printed to the exact size breakdown you submit, so a wrong guess cannot be swapped after production. Groups that estimate a split almost always end up with too many of one size and too few of another. Youth and adult sizing adds another layer: a school or league that lumps everyone into adult sizes leaves younger kids swimming in their shirts.

The fix is to collect real sizes before you place the order. A short form, a sign-up sheet at practice or a reply-all email with a deadline works far better than a guess. Ask for youth or adult, the size, and a fit preference if the order mixes unisex and women's cuts.

• Set a firm deadline for size responses and order on that date.
• Share a size chart so people compare against a shirt they already own.
• Add a few spares in the most common sizes for late sign-ups and new members.
• Keep youth and adult sizes separate on your list so nothing gets mixed up.

If you are not sure how many shirts to order in total, the Quokka Prints guide on how many custom shirts to order for an event explains how to plan the count and the spares.

What artwork mistakes slow down a custom shirt order?

The artwork mistakes that slow down a custom shirt order most are low-resolution logos, missing fonts, unclear color choices and designs with tiny details that cannot print cleanly. A logo saved from a website header or screenshot from a phone often looks fine on screen but prints soft once it is enlarged across a shirt front. Thin lines and very small text can also fill in or disappear, especially on textured fabric or embroidery.

Send the best file you have. Vector files such as AI, EPS, SVG or a vector PDF are ideal, and a large, high-resolution PNG is the next best option. If all you have is a rough sketch or a low-quality image, say so up front. Quokka Prints creates free custom artwork within 24 hours, so the team can redraw or clean up a logo instead of printing a blurry one.

• Tell the designer which colors are official, especially for school or company brand colors.
• Keep wording short for sleeve and back prints so the text stays readable.
• Avoid placing light ink on light shirts or dark ink on dark shirts without checking contrast.

For file types, print areas and color tips in detail, read the Quokka Prints logo file guide for custom shirts before you send your design.

How does choosing the wrong shirt or decoration method go wrong?

Choosing the wrong shirt or decoration method goes wrong when the garment does not match how people will actually use it. A heavy cotton tee looks great at a fall fundraiser but feels hot and damp at a summer race. A detailed full-color photo can be a poor fit for embroidery, and a tiny run of many different names can be better suited to digital printing than screen printing. The best choice depends on the event, the climate, the design and how long people will keep wearing the apparel.

If your group needs	Common mistake	Better choice
Race or practice shirts	Heavy cotton that holds sweat	Polyester performance tees, with sublimation for all-over designs
Staff or work shirts	Thin event tees that wear out quickly	Polos or blends with an embroidered logo
Bold, simple logos in volume	Paying attention only to looks on a screen	Screen printing on a soft ringspun cotton tee
Full-color or photo-style art	Forcing detailed art into embroidery	Digital (DTG) printing on cotton
Fall and winter wear	Ordering only tees	Hoodies or crewneck sweatshirts

You do not need to become an apparel expert to get this right. Tell Quokka Prints who will wear the shirts and where, and the team will recommend a blank and a decoration method that fit. The screen printing vs embroidery page explains how the two most popular methods compare.

What timing mistakes make custom shirts arrive too late?

The timing mistakes that make custom shirts arrive too late are starting the order too close to the event, leaving size collection until the last minute and waiting days to approve the proof. Production at Quokka Prints typically takes 7 to 14 business days after proof approval, plus 3 to 4 days of free shipping. Business days skip weekends and holidays, so a deadline that feels comfortable on the calendar can be tighter than it looks.

Plan backward from the day the shirts must be in hand. Leave time for the artwork round, time to gather sizes, time for any revisions and the full production and shipping window. Give yourself a cushion of a few extra days so you can sort the shirts by size or by team before handing them out.

1. Pick the date the shirts must be in hand, not the event date itself.
2. Count back the shipping days and the production business days.
3. Add time for artwork, revisions and collecting sizes.
4. Start the order on or before that date, and approve the proof promptly.

If the date is already close, ask about rush production when you request a quote. Rush is available on many orders, and the team will tell you honestly what is realistic for your timeline.

Why can focusing only on the cheapest option backfire?

Focusing only on the cheapest option can backfire because the lowest-cost blank or the fewest print locations rarely match what the group really wanted. A thin shirt that nobody wears after the event costs more in the long run than a softer one that people keep wearing to games and school pickups. Hidden extras from some suppliers, such as setup charges or separate shipping fees, can also make a quote that looked low end up higher.

Compare quotes on the same garment, the same print locations and the same quantity, and ask what is included. Quokka Prints charges no setup fees, includes free standard shipping and offers a price match guarantee, so you can choose the shirt that fits your group without worrying about surprise line items.

• Ask whether setup, screens and shipping are included in the quote.
• Compare the exact same blank and print locations, not just a headline number.
• Think about how often the apparel will be worn when choosing quality.
• Consider a front print only if the back print is not essential to the design.

Pricing depends on the garment, the number of colors and print locations, the decoration method and the quantity. Share those details when you get started and the quote will reflect exactly what you are ordering.

What should you check on the proof before approving a custom shirt order?

Before approving a custom shirt order, check the proof for spelling, colors, logo placement, print size, shirt color and the full size breakdown. The proof is the last chance to catch a mistake before production starts, and most reprint headaches come from a proof that was approved on a phone in a few seconds. Open it on a larger screen and ask a second person to read every word.

1. Spelling and wording: names, dates, school or company names and any small print.
2. Colors: ink colors and shirt colors match what you asked for.
3. Placement: front, back and sleeve locations are where you expect.
4. Size of the design: the logo looks right for the chest or back, not too small or too wide.
5. Quantities and sizes: the size breakdown matches your final list, including youth sizes.
6. Delivery details: the ship-to address and the in-hand date are correct.

Ask for changes as often as you need before approving. Once everything looks right, approve the proof quickly so production can start and your timeline stays on track.

How does Quokka Prints help first-time buyers avoid these mistakes?

Quokka Prints helps first-time buyers avoid ordering mistakes by guiding the order from artwork to delivery. You can start from scratch or send your own design, and the team returns free custom artwork within 24 hours along with a recommendation for the shirt and decoration method that suit your group. There are no setup fees, minimums start as low as 10 to 25 pieces depending on the product, and standard shipping is free.

The team decorates with screen printing, embroidery, digital (DTG) printing and sublimation, so the method fits the design instead of the other way around. More than 5,000 organizations, including PTAs, schools, camps, sports leagues, nonprofits and companies, have trusted Quokka Prints, and the business holds a 5-star Google rating.

When you are ready, use the get started form to share your idea, your rough quantity and your in-hand date. If your group needs a large order, the bulk custom t-shirts page explains how to organize sizes and colors for a big run.