bespoketshirt.com

Step 1: Design & Pre-Press

Artwork Preparation: We receive vector artwork (AI, EPS, or high-res PDF at 300+ DPI) with transparent backgrounds.

Color Calibration: Colors are separated and calibrated against standard Pantone swatches to ensure complete color fidelity between screen preview and physical production.

Digital Sign-off: Detailed digital mockups and proofs are shared for client approval before entering the printing phase.

Step 2: Transfer Film Production (DTF / Screen Transfer)

Dual-Layer Printing: Specialized high-speed printers print the colored ink layer first, followed directly by a solid, opaque white backing layer.

Powder Coating: Hot-melt adhesive polyurethane powder is evenly distributed across the wet ink layer.

Oven Curing: The film passes through a curing tunnel (110℃–130℃) to melt and set the adhesive onto the film.

Step 3: Garment Preparation

Blank Inspection: Every blank garment is individually checked for fabric defects, sizing consistency, and surface flaws.

Pre-Press Treatment: Garments are heat-pressed for 3–5 seconds before printing to release fabric moisture and flatten any surface creases, ensuring a smooth base.

Step 4: Heat Press Application

Precision Placement: The transfer film is aligned on the garment platen using infrared laser guides or physical alignment rulers.

Calibrated Transfer: Industrial pneumatic heat presses apply medium-to-firm pressure at 150℃–160℃ for 12–15 seconds to permanently fuse the print into the fibers.

Step 5: Peeling & Fixing

Carrier Release: Depending on the film specifications, the clear PET backing film is peeled away smoothly (hot peel or cold peel).

Secondary Press: A secondary 3–5 second post-press is performed with a protective Teflon sheet to seal the edges, enhance hand-feel, and lock in wash durability.

Step 6: Quality QC & Packaging

Visual & Stretch Inspection: Each finished shirt is hand-inspected and undergoes an elasticity/stretch test to ensure no cracking or lifting occurs.

Wash Testing: Samples from each production lot undergo standard 40°C machine washing cycles to verify color fastness and adhesion.

Branding & Export Packing: Custom neck labels and hangtags are attached. Shirts are folded neatly, placed in individual barcode-labeled polybags, and packed into heavy-duty export master cartons ready for global dispatch.