Putting your logo on a piece of apparel is one of the best ways to get noticed in this industry. According to the 2022 State of the Industry, T-shirts were once again the #1 promo product last year, accounting for an astounding 15.7% of all distributor promo revenue. In fact, apparel of all sorts reigned supreme, with Polos (9.4% revenue share), Caps/Headwear (9.3%), Wearables – Non-Shirts (5.3%) and Shirts-Other (3.5%) also landing in the top 10.

But when it comes to apparel, not every imprint method is created equally. There are decoration styles that fit with different fabrics at all budgets levels. So let’s break down what to look for when placing your decoration orders.

Decoration Techniques

The first step in deciding which decoration method is right for you is to understand the strengths of each technique and how you can apply it to your product.

• Embroidery – For promo purposes, embroiderers typically use computers to stitch decorative designs on a piece of clothing.
  Ideal for: Polo shirts, sweatshirts
  
  
• Heat Transfer – Ideal for small-batch imprinting, this method uses a heat press to apply a logo onto a garment.
  Ideal for: T-shirts, jerseys
  
  
• Dye Sublimation – This form of printing uses digital print technology to produce full-color, photo-quality images. Dyes are fused into polyester (or poly blends) using heat or pressure.
  Ideal for: Performance apparel, flip flops
  
  
• Deboss – Debossing creates a tonal 3D look with plenty of detail. It’s applied by compressing fabric with a metal plate under very high pressure and temperatures.
  Ideal for: Tech fabrics, baseball hats
  
  
• Screen Printing – This stencil-printing process creates a pattern by forcing ink onto a surface through a screen of fine material, like woven mesh. There are many specialty inks available to create a wide variety of effects.
  Ideal for: T-shirts
  
  
• Other – While the above methods are the most common, there are many other hybrid decoration methods that take traditional techniques a step further, like sequin embroidery, woven-in, laser tech applique and ProSpangle.

New Twists on an Old Classic

Of all the methods mentioned above, heat transfer emerged as one of the most popular in the industry. Not only is it available in a variety of options (full-color, digital transfer, patches, emblems, etc.), but it’s also an easy technique for distributors to learn themselves on an in-house heat press. Even if DIY imprinting isn’t in the cards for your company, there are still plenty of ways to get creative with this industry staple to help you stand out from the competition.

One of the simplest ways to apply this decoration method is with direct-to-film transfer, which made a lasting impression at ASI Orlando thanks to Stahls’ (asi/88984) launching its UltraColor MAX, a product that takes a full-color or fine-detail logo and enhances it without an outline or scorching. The versatility and efficiency of direct-to-film transfers allows distributors to become a one-stop solution for their clients. Direct-to-film transfers can be applied to a variety of surfaces, going beyond apparel to products like bags and blankets, meaning you can kit multiple items together with the same logo to increase your average order value.

If you want to add some dimension to your logo, patches and emblems are a popular choice. Giving a textural look and feel to caps and other headwear is trendy, and their application can be applied to other items like bags, coats, padfolios and other hard goods. Since they’re easy to apply, patches are also great for live demonstrations, and giving clients an interactive element to your sales pitch will help you stay top of mind. With low minimums and quick turnaround times, this method has mass appeal.

With a variety of colors and finishes available with heat transfer vinyl, it’s easy to get creative, so don’t be afraid to try some special effects. One way to accomplish this is to produce a limited-edition version of a client’s logo by rendering it in glitter or metallic vinyl, which allows the logo to pop for brand anniversaries or other special celebrations without much additional effort. Color-changing vinyl – whether glow-in-the-dark or sunlight-reactive – is also in style and gives a fun, interactive element to themed designs. Remember: less is more when it comes to specialty vinyl. Stick to one or two colors to maximize the impact.

Sometimes it pays to think outside the box when decorating your apparel. While left-chest logos are a classic look that will always be in style, sometimes circumstances call for getting creative with logo placement. There are a number of ways to increase brand visibility by breaking your customers’ expectations of where the logo shows up. Add a secondary brand element on the back of the neck or the hem of a shirt. Colleges often put messaging down shirt sleeves and pant legs. You can also wrap the logo or messaging around the side/brim of a cap or personalize the back of the cap with names or player numbers. Don’t be afraid to try something different!

While heat transfer is trending up, there are plenty of other new and unique methods to keep an eye on, many of which put a spotlight on two of the most pressing issues for distributors nowadays – affordability and sustainability. Name Badges International, a division of Top 40 supplier World Emblem (asi/98264), recently added borderless plastic name badges to their product line. These economical badges are available in full-color printing, come in a wide range of colors and can be fitted with a pin or magnetic fitting. With no minimum order, setup fees or design fees, they are fully customizable decoration offers that can fit any business or budget. On the sustainability side, Beaver Paper, a manufacturer of sublimation media and sewn paper products, recently launched the TexSeal Eco Pouch – sustainable paper packaging made from renewable forest products. As a 100% recyclable and biodegradable alternative to plastic, this packaging solution is one of the many ways to cater to the overwhelming demand for eco-conscious promo solutions.

Expand Your Capabilities with Decoration Equipment

One of the most streamlined ways to get in on some of these trending decoration methods is to invest in your own decoration equipment. With a little research and training, this upfront cost will save you a lot of money in the long run. Here are just a few of the latest innovations in digital imprinting and laser-engraving equipment designed to help promo distributors and apparel decorators grow their businesses and become more efficient:

• Epson Monna Lisa 8000 Digital Direct-to-Fabric Printer – The first direct-to-fabric printer available in North America has been 20 years in the making. Built for both short runs and larger-volume orders, this printer delivers crisp textile prints at industrial-level speeds and can accurately reproduce complex patterns, color gradations and photographic detail to cotton, polyester, silk, wool and blends.
• AP Lazer SN2616LR Laser Machine – This entry-level laser machine is designed for beginners with a low-rider carriage cart that can engrave any object without size or weight limitations. In addition to appeal, it can be used on everything from furniture to floors to wine bottles.
• Kornit Atlas MAX Poly – A direct-to-garment solution, this printer enables high-quality digital decoration in vibrant colors on polyester and poly blends. It’s a game-changer when it comes to decorating the ever-popular sportswear and athleisure market.
• Vastex Lo-E Dryer – This energy-efficient machine cures digital white ink, digital CMYK and DTG pretreatment at a rapid rate while using 20% less energy than comparable dryers. The modular designs make increasing production needs easy by expanding chambers and conveyor lengths.

Have you had any experience with the decoration methods we discussed? Do you have a favorite that has worked for you? Continue the discussion on our members-only Facebook page.