Garment Printing & Materials Guide | Kitroom Football

1. Digital & Single-Unit Methods

• Production Lead Time: Approx. 5 business days
• Minimum Order Quantity (MOQ): 1 unit

Cut Vinyl (CAD-Cut)

• The Process: A precision plotter mechanically cuts a thin polyurethane (PU) film of a solid color based on a vector file. Excess material is hand-weeded, and the transfer is applied with a heat press.
• Why it’s accessible: The machine works directly from a digital file—no screens or film positives to prepare.
• Production Time & MOQ: ~5 business days | From 1 unit.
• Specialty Colors (Metallic & Neon): YES. Available in genuine pre-dyed metallic flex (gold, silver) and bright neon/fluorescent colors.
• Dye-Bleed Protection Note: Even though the backing of cut vinyl is smooth and white, high-quality PU flex vinyl features built-in dye-stop properties to prevent shirt dyes from bleeding through.
• Finish & Best For: Ultra-sharp edges for simple text or modern single-color numbers and quick individual orders.

Digital Print Vinyl

• The Process: A printer using eco-solvent or latex inks prints the design in full color onto a white printable vinyl film, which is then contour-cut around the edges.
• Why it’s accessible: Works like a desktop printer on vinyl, allowing full-color crests or logos to be produced straight from the computer.
• Production Time & MOQ: ~5 business days | From 1 unit.
• Specialty Colors (Metallic & Neon): NO. True metallic inks or fluorescent neon pigments cannot be printed. All gold, silver, or neon effects are flat CMYK visual simulations.
• Dye-Bleed Protection Note: Includes an integrated block-out layer despite having a smooth white backing.
• Finish & Best For: Supports shading and gradients without setup costs, offering a slightly thicker, “sticker-like” feel for full-color badges and logos.

DTF (Direct to Film)

• The Process: The design is printed onto a PET film using water-based textile inks, backed with a white ink layer and a hot-melt adhesive powder, then cured in an oven before pressing.
• Why it’s accessible: The modern digital standard for printing detailed full-color graphics for single garments without making physical molds.
• Production Time & MOQ: ~5 business days | From 1 unit.
• Specialty Colors (Metallic & Neon): NO. Cannot produce true metallic or neon inks. Metallic or neon elements are visual CMYK color approximations.
• Finish & Best For: Thin, elastic, and soft hand-feel. Ideal for complex graphics, multi-color logos, or modern details where traditional screen printing is not cost-effective for small runs.

2. Hybrid Methods

Plastisol HD

• The Process: Combines high-resolution digital printing (CMYK) for top-layer details with an industrially screen-printed white plastisol backing layer applied via a screen on the rear.
• Production Time & MOQ Limitations:
  • Production Lead Time: 30 to 45 business days
  • Minimum Order Quantity (MOQ): 25 units per model/design
  • Why the higher cost for small runs?: Because this method involves preparing physical screen setups at the factory, producing fewer than 25 units per design is either not permitted by production or results in a significantly higher cost per unit that is rarely cost-effective for single shirts.
• Specialty Colors (Metallic & Neon): SOMETIMES. Depending on the artwork structure and specific screen setup, true metallic or neon accents can occasionally be integrated, though it is not standard for all designs.
• Dye-Bleed Protection & Backing Note: Anti-migration protection is integrated when intended for dark polyester shirts. On white or light-colored shirts where dye migration cannot occur, the blocker layer is omitted to keep the transfer lighter and more flexible.
• Finish & Best For: Provides the elasticity, body, and textile adhesion of traditional plastisol ink while reproducing intricate crests, multi-color sponsor logos, or gradient graphics.

  

3. Traditional Screen-Printed Plastisol

Why does screen printing require a complex setup?

Unlike digital methods, traditional screen printing cannot print directly from a computer file. It requires an industrial multi-step process: color separation into film positives, screen mesh exposure, custom Pantone ink mixing, mechanical screen registration, and high-temperature oven curing.

Plastisol Screen Printing (Spot Colors) — The Top Quality Standard

• The Process: Direct industrial printing of pure plastisol ink layers through precision screen meshes for maximum durability, vibrant colors, and premium texture.
• Production Time & MOQ Limitations:
  • Production Lead Time: 30 to 45 business days
  • Minimum Order Quantity (MOQ): 25 units per model/design
  • Why single units are costly: Preparing individual screens, mixing custom Pantone inks, and setting up industrial machinery carries fixed costs. For orders under 25 units per design, factory setups make single-unit manufacturing price-prohibitive.
• Specialty Colors (Metallic & Neon): YES. Full capability for genuine metallic inks (Pantone gold, silver, metallic bronze) and vibrant neon/fluorescent Pantone inks.
• Anti-Migration Protection & Backing: By default, our plastisol transfers include a dedicated carbon/blocker rear barrier layer (black or dark grey) to block shirt dye sublimation on dark or vibrant polyester jerseys (red, navy, black, green).
• The Light-Shirt Exception: In specific exceptions (such as white or very light-colored shirts), the anti-migration layer is omitted simply because dye migration is physically impossible on those fabrics. Leaving out the blocker on light shirts keeps the print ultra-thin, flexible, and soft without reducing quality or durability.
• Finish & Best For: The highest quality grade available. Essential for long-lasting, professional-grade prints with 100% color accuracy and superior wash resistance.

Summary Selection Table