Ordering custom shirts in bulk is a great way to promote your brand, unify a team, or create merchandise for an event. However, simple mistakes can lead to unexpected costs, delays, or low-quality results. At KDI Print & Embroidery, we help businesses and organizations get the perfect custom apparel every time. Here are four common mistakes to avoid when placing a bulk order.
4 Common Mistakes to Avoid When Ordering Custom Shirts in Bulk

Choosing the Wrong Shirt Material
Not all T-shirts are created equal. The material you choose affects comfort, durability, and print quality. Cotton is soft and breathable, while polyester blends offer moisture-wicking properties. If you’re unsure which fabric is best for your needs, our team can help you select a high-quality option that fits your budget and purpose.

Overlooking Design Details
A great design can make or break your custom apparel. Small fonts, overly complex graphics, or low-resolution images can result in poor print quality. We recommend using high-resolution files and ensuring your design is clear and visually appealing. Our experts can also assist with adjustments to make sure your logo or artwork looks sharp on every shirt.

Ordering the Wrong Sizes
One of the biggest mistakes when ordering in bulk is misjudging size distribution. If you’re ordering for a large group, it’s important to consider different body types and have a range of sizes available. We can help you determine the best quantity breakdown based on common size trends to ensure everyone gets a great fit.

Ignoring Turnaround Times
Last-minute orders can lead to unnecessary stress and rush fees. Custom shirt printing takes time, especially for large orders. To avoid delays, we recommend placing your order well in advance—especially for events or seasonal promotions. Our team works efficiently to meet deadlines, but early planning always ensures the best results.
Avoiding these common mistakes will help ensure a smooth ordering process and high-quality results. At KDI Print & Embroidery, we’re here to guide you every step of the way, from selecting the best materials to perfecting your design. Ready to place your bulk order? Contact us today to get started!