Custom Screen Printing & Embroidery — Frequently Asked Questions
Have a question about your order, our process, or which printing method is right for your project? Mallory Print produces custom apparel in-house, and we’ve heard just about every question there is. If yours isn’t answered here, call us at (817) 558-0804 or email ethan@malloryprint.com — we respond fast.
- Mallory Family Business Est. 1961
- Family owned
- In-house production
- Best pricing at 24+ pieces
- Fully customizable
- Affordable pricing
Ordering & Minimums
What is the minimum order for screen printing?
Our minimum for screen printing is 12 pieces. Volume discounts begin at 24 pieces and above — that’s the threshold where per-unit pricing drops most noticeably, color consistency improves across the run, and screen printing delivers its best value. For quantities under 12, we offer DFT (Direct Film Transfer) with no minimum at all.
What is the minimum order for embroidery?
Our minimum for embroidery is 12 pieces. Embroidery setup involves digitizing your design into a stitch file, and that cost is spread across the run — so larger quantities mean a lower cost per piece. Call us at (817) 558-0804 to discuss your project and get a quote.
Can I mix sizes in a single order?
Yes. You can mix sizes — S through 3XL or any range — and all pieces count toward your 12-piece minimum. If your combined quantity hits 24+, volume pricing applies across the whole order. Just provide a size breakdown when you request your estimate and we’ll factor it in from the start.
Can I bring in my own garments to be printed or embroidered?
Yes, we accept customer-supplied garments. We ask that all items are new or freshly cleaned before you bring them in. Keep in mind that we cannot guarantee results on garments with unknown fabric compositions or pre-existing damage.
Do you offer fulfillment and packaging services?
Yes. We offer different levels of packaging and shipping fulfillment depending on the needs of your order. If you need individual packing, poly-bagging, or direct-to-recipient shipping, let us know when placing your order and we’ll walk you through the available options.
Can I reorder the same design later?
Yes. We keep artwork on file, which makes reorders straightforward. If you’re reordering a screen printing job, screens may need to be remade depending on how much time has passed, but having your original files on record speeds up the process significantly. Mention it’s a reorder when you contact us.
Pricing & Quotes
How do I get a price quote?
Fill out the estimate form on our Contact page, call us at (817) 558-0804, or email ethan@malloryprint.com. We respond to all quote requests within 24 hours. Have your artwork, approximate quantity, garment type, and number of print colors ready and we can turn a quote around quickly.
How much does custom screen printing cost?
Pricing depends on the number of pieces, number of print colors, garment type, and print locations. Screen printing gets significantly more affordable per piece as quantity increases — orders of 24 or more are where pricing really starts to work in your favor. We don’t list fixed prices on the site because every order is different, but we turn around free estimates in 24 hours. Contact us to get your number.
Does a larger order reduce the price per piece?
Yes, significantly. Screen printing pricing drops as quantity increases — the setup cost (screens, ink mixing, press calibration) is a fixed expense spread across the full run. Volume discounts begin at 24 pieces and continue to improve from there. Orders at 12–23 pieces are still priced fairly, but if you can push an order to 24+, the per-unit savings are real and worth planning for.
Are there setup fees?
Yes, we accept customer-supplied garments. We ask that all items are new or freshly cleaned before you bring them in. Keep in mind that we cannot guarantee results on garments with unknown fabric compositions or pre-existing damage.
Do you offer rush orders?
Yes. For an additional fee, we can expedite production on standard-sized orders to a couple of days. Rush availability depends on current production volume, so the sooner you let us know about a deadline the better. Contact us as early as possible if timing is critical. Call (817) 558-0804 or email ethan@malloryprint.com.
Artwork & Design
What file format does my artwork need to be in?
We prefer vector files: .ai, .eps, or .cdr. These scale without losing quality and are the cleanest format for screen printing production. We also accept .psd, .paf, .png, and .jpeg at the highest resolution available — 300 dpi or higher at print size. If you’re not sure whether your file will work, send it over and we’ll take a look.
Do you offer graphic design services?
Yes. We have in-house graphic designers who can develop artwork from scratch, refine a rough concept, prepare an existing file for production, or build a logo if you don’t have one. If you have an idea but no finished file, bring it to us — a sketch, a reference image, or even a description — and our team will handle the rest. Design work is quoted separately from your print order.
What if my artwork needs to be adjusted for printing?
Some designs need minor modifications to work cleanly in screen printing — color separation, minimum line width adjustments, or converting raster images to vectors. Our team handles these adjustments and will communicate any changes before production begins. For significant redesigns, there may be a design fee.
How many colors can my design have?
Screen printing handles designs with one to approximately six spot colors well. Each color requires a separate screen, so more colors mean higher setup costs. For designs with many blended colors, gradients, or photographic detail, DFT printing is often the more practical option. If you have a complex design and aren’t sure which method fits, send it to us and we’ll give you a recommendation.
Will I see a proof before production starts?
Yes. We provide a digital proof for your approval before any production begins. We do not start printing until you have reviewed and approved the proof. If something looks off — color, placement, sizing — that’s the time to catch it and we’ll adjust before your order goes to press.
Screen Printing
What is screen printing?
Screen printing is the process of pushing ink through a mesh stencil directly onto a garment, one color at a time. Each color in your design requires its own screen. After printing, the ink is cured at high heat, bonding it to the fabric fibers for a durable, long-lasting finish. It’s the industry-standard method for bulk custom apparel and produces bold, vibrant color that holds up wash after wash.
How long does screen printing last?
A properly cured screen print should last the life of the garment with normal care. The ink curing process bonds the ink to the fabric at a molecular level, which is why screen printing is significantly more durable than most heat-applied methods. To maximize longevity, wash garments inside out in cold water and avoid high-heat drying.
What fabrics can be screen printed?
Screen printing works best on smooth, absorbent fabrics — cotton and cotton-polyester blends are the most common and produce the best results. Highly textured fabrics, slick synthetics, and heat-sensitive materials can present challenges. If you have a specific fabric you’re working with, let us know and we can advise on the best approach.
Can you screen print on dark-colored garments?
Yes. Printing on dark fabrics typically requires an underbase — a white ink layer applied first to keep colors vibrant and true on dark backgrounds. This adds a step to the process and factors into pricing, but the results are clean and professional. We handle underbase printing routinely.
What is the largest print area available for screen printing?
Standard screen printing covers up to approximately 14″ x 16″ on a standard front or back chest print. Oversized prints are available — contact us with your design and we can confirm sizing and any additional requirements.
What's the difference between screen printing and heat transfer printing?
Screen printing applies ink directly to the garment through a stencil and cures it permanently into the fabric. Heat transfer printing applies a pre-printed design to the garment using heat and pressure. Screen printing is more durable for long-term, high-wash-frequency use. Heat transfers can be a practical option for very small quantities or highly detailed designs where screen setup costs aren’t justified.
DFT Printing
What is DFT printing?
DFT stands for Direct Film Transfer. It’s a printing method where your design is digitally printed onto a special transfer film and then heat-applied to the garment. Unlike screen printing, DFT requires no screens and has no minimum order quantity — making it the right call for very small runs, one-offs, or designs with complex gradients and fine detail that would require many screens to reproduce.
What is the difference between DFT and screen printing?
Screen printing uses ink pushed through a mesh stencil and permanently cured into the fabric — more durable and more cost-effective as quantity grows, with volume discounts beginning at 24+ pieces. The minimum for screen printing is 12 pieces. DFT transfers a digitally-printed film using heat — no screens, no minimums, and better suited for complex multi-color artwork or runs under 12 pieces. For long-term, high-use items like uniforms or spirit wear, screen printing wins on durability. For runs under 12 or designs with intricate gradients, DFT is the smarter call.
Is DFT the same as DTG (Direct to Garment)?
No. DFT (Direct Film Transfer) and DTG (Direct to Garment) are different processes. DTG prints directly onto the garment using an inkjet-style printer. DFT prints onto a film first, then transfers that film onto the garment using heat. Mallory Print offers DFT — not DTG. Both are alternatives to screen printing for small runs and complex designs, but they produce different results and have different material requirements.
What fabric works best for DFT printing?
DFT adheres best to cotton, polyester, and cotton-poly blends. It works well on both light and dark garments. If you have a specific fabric or garment in mind, reach out and we’ll confirm compatibility before you commit to an order.
Custom Embroidery
What is embroidery digitizing?
Digitizing is the process of converting your artwork or logo into a stitch file — a set of instructions that tells the embroidery machine exactly where to stitch, in what direction, and with what thread color. Every embroidery job requires digitizing, and the quality of the digitizing directly affects how clean and professional the finished embroidery looks. We handle all digitizing in-house.
What items can be embroidered?
We embroider hats (structured and unstructured), polo shirts, jackets, hoodies, uniforms, bags, and more. If you have a specific item in mind that isn’t on this list, contact us and we’ll let you know if it’s workable.
Can you embroider on hats?
Yes. Hat embroidery is one of our most common requests. We work with structured caps, unstructured hats, and beanies. Hat embroidery has different technical requirements than flat-surface embroidery — the curved surface affects stitch placement and design sizing — and our in-house team accounts for those factors during digitizing.
What is the difference between screen printing and embroidery?
Screen printing applies ink to the surface of a garment — it’s flat, vibrant, and ideal for large or colorful designs on t-shirts and similar items. Embroidery stitches your design directly into the fabric using thread — it’s raised, textured, and carries a more professional, premium look. Embroidery is generally preferred for logos on uniforms, polos, and hats. Screen printing is typically better for large graphic designs, event shirts, and volume orders. Many businesses use both.
How do I care for embroidered garments?
Wash embroidered items inside out on a gentle cycle with cold water. Avoid bleach and high-heat drying, which can damage threads over time. Embroidery is inherently durable — the stitching is part of the garment — but proper care will keep it looking sharp for years.
Do you make custom embroidered patches?
Yes. We produce custom embroidered patches — iron-on, sew-on, and with hook-and-loop backing. Patches are a good option when you want embroidered branding on items that can’t go through an embroidery machine, or when you want interchangeable branding across multiple garment types.
Turnaround & Shipping
What is your standard turnaround time?
What is your standard turnaround time? Our standard turnaround from order approval to completion is approximately:
- 5-7 business days for Screen Printed apparel.
- 8-10 business days for Embroidery depending on availability.
- Faster turnaround is available.
Larger or more complex orders may take longer. Turnaround depends on order size, current production volume, and product availability. We’ll give you a confirmed timeline when your order is placed — not a vague estimate.
Do you offer rush production?
Q Do you deliver locally?
Do you ship nationwide?
Yes. Mallory Print ships custom printed and embroidered apparel to customers in all 50 states. The Mallory family has been shipping nationwide since 1961. Contact us for shipping options and estimated delivery times based on your location and order size.
About Mallory Print
Where is Mallory Print located?
We are located in Joshua, TX, in Johnson County, just south of Burleson and approximately 30 minutes from Fort Worth. We serve businesses, schools, teams, and organizations throughout the DFW Metroplex and ship nationwide.
Phone: (817) 558-0804 | Email: ethan@malloryprint.com | Hours: Monday–Friday, 8:00 AM–5:00 PM
How long has the Mallory Family been in business?
Is all production done in-house?
Still Have a Question?
We’re a family-owned shop in Joshua, TX — not a call center, not a chatbot. If you have a question about an order, a deadline, or which printing method is right for your project, reach out. We know our stuff and we get back to you fast.”