Ordering custom workwear for your trade or construction business should be straightforward. You want your crew looking professional, your brand on display, and gear that can handle the demands of the job site. Simple, right?
Well, not always.
At ZZZZ BEST TEES, we've seen plenty of workwear orders go sideways : not because the customer didn't care, but because they fell into some common traps. The good news? These mistakes are completely avoidable once you know what to look out for.
Whether you're kitting out a plastering crew, a concrete team, or a joinery workshop, here are the seven biggest mistakes we see trade businesses make with custom workwear orders : and how to dodge them like a pro.
Here's a scenario we see all the time: a sparkie sends through a logo with seven colours, intricate gradients, and fine details. They want it screen printed because "that's what everyone does."
The problem? Screen printing charges per colour. Every additional colour means another screen, another setup fee, and a higher per-unit cost. For complex, full-colour logos, screen printing can get expensive fast : especially on smaller runs.
This is where DTF (Direct-to-Film) printing changes the game.
With DTF, your artwork is printed in full colour without the need for separate screens. That means your detailed logo with gradients, shading, and multiple colours costs the same as a simple one-colour design. There are no setup fees, making it perfect for small to medium runs where screen printing setup costs would blow out your budget.
The fix: If your logo has more than two or three colours, or includes photographic elements and fine detail, DTF printing is almost always the smarter choice. You get vibrant, sharp results without the price tag of multi-colour screen printing.
Not all fabrics are created equal : especially when your team is working outdoors in Australian conditions.
We've seen businesses order 100% cotton tees because they're "classic," only to find out the hard way that cotton holds sweat, takes forever to dry, and can shrink after a few washes. On the flip side, some go straight for polyester without realising it can feel like wearing a plastic bag on a 35-degree day.
Here's the breakdown:
The fix: Think about where your crew works. Concrete crews baking in the sun need something different from cabinet makers in an air-conditioned workshop. When in doubt, check out our garments and printing technology page or ask us for a recommendation.
This one stings.
Order too many shirts and you've got boxes of XL tees gathering dust in the shed because Dave quit and no one else is that size. Order too few and you're scrambling to place a rushed reorder when the new apprentice starts : often at a higher per-unit cost.
The old screen printing model made this worse because setup fees encouraged bulk ordering. You'd order 100 shirts to bring the unit price down, even if you only needed 30.
DTF printing flips that equation.
Because there are no screens to set up, ordering 15 shirts costs the same per unit as ordering 50. You can order exactly what you need now and easily reorder later without penalty. Need five more polos next month when you hire a new chippie? No problem.
The fix: Start with what you actually need. Poll your team for sizes (seriously, just ask : it takes two minutes), factor in a couple of spares, and know that topping up later is easy and affordable with DTF.
Nothing halts a workwear order faster than a blurry logo pulled from your Facebook page or a tiny JPEG from 2015.
For the best print results, your artwork needs to be high resolution : at least 300 DPI for raster images (like JPEGs and PNGs). Even better, send a vector file (AI, EPS, or PDF) if you have one. Vector files can be scaled to any size without losing quality, which means your logo looks crisp whether it's on a small chest print or a massive back panel.
The fix: Dig out the original logo files from when your brand was designed. If you don't have them, a good print shop can sometimes recreate or vectorise your logo : just ask. And once you have quality files, keep them somewhere safe so you're not hunting for them every time you reorder.
We get it. You're flat out running jobs, chasing invoices, and managing a crew. Ordering new uniforms isn't exactly top of the to-do list until you suddenly realise the company Christmas party is in two weeks and half the team is wearing faded gear with the old logo.
Custom apparel takes time. Even with efficient processes, you need to account for artwork approval, production, and shipping. Rush jobs are possible, but they're stressful : and sometimes come with rush fees.
The fix: Plan ahead. If you know you've got new staff starting, a trade show coming up, or a rebrand in the works, get your order in early. A good rule of thumb is to allow at least two to three weeks for standard orders. Need it faster? Request a quote and we'll let you know what's possible.
You've sent your logo, picked your shirts, and you're keen to get things moving. So when the digital proof lands in your inbox, you give it a quick glance and fire back "looks good."
Then the order arrives and... the logo is 20% smaller than you expected. Or the phone number has a typo. Or the placement isn't quite where you imagined.
The fix: Take five minutes to actually review the proof. Check the logo size, placement, spelling, and colours. If something looks off, say so : it's much easier to fix before production than after. For larger orders, consider requesting a sample shirt first so you can see the print quality, fit, and feel in person.
Your workwear is a walking billboard for your business. When a potential client sees your crew on a job site, you want them to see a professional, cohesive team : not a mishmash of different logo sizes, faded prints, and inconsistent colours.
This often happens when businesses order workwear sporadically from different suppliers, or don't keep track of their logo specifications. One batch has the logo at 10cm wide, the next at 8cm. One order uses the updated phone number, another still has the old one.
The fix: Stick with one supplier who keeps your artwork and specifications on file. That way, every reorder matches the last. At ZZZZ BEST TEES, we keep records of your logo files, print placements, and past orders so your gear stays consistent : whether you're ordering five shirts or fifty.
Custom workwear doesn't have to be complicated. By avoiding these seven common mistakes, you'll save money, reduce stress, and end up with gear your team actually wants to wear.
And if you're ready to kit out your trade or construction crew with high-quality DTF printed workwear : vibrant colours, sharp detail, no ridiculous setup fees : we're here to help.
Get a quote today or start designing your custom gear. Let's make your crew look as good as the work they do.
