Print Work FAQ


Contract in-house embroidery now available.

Digitizing is the programing that tells the embroidery machine how to stitch your art, all art needs to be prepared by digitizing software. We charge $45 as a one time set up fee. This covers the digitizing, thread color matching and a pre production sew-out photo for approval. All customer art and job information is stored on our cloud database making for easy reproduction with no reset setup fees.

We can take art in almost any format but it is preferred that you submit your art as a vector. We know that this portion of the process can be confusing so just reach out to us with any questions and we’ll take care of it. We do offer in-house design work if those services are needed.

Contract Sewing

With The Foundry’s in-house finishing department you’ll find all your solutions for hat patches, badging and labeling. Combined with our vast label/patch sourcing capabilities this is your one-stop shop for custom headwear and private label.

Want to learn more aobut patches and labeling? Check out the links below.

Labeling 101 and Terminologies

Custom Patches and Woven Labels Defined


Learn about some of the more common screen printing systems and methods.

Much like a dye process water-based and water-based discharge are water born systems where the print ink is absorbed into the fabric. This creates a softer, longer lasting and more environmentally friendly screen printing process. Although there are some poly blended fabrics that are compatible with water-based printing it’s recommended that only 100% cotton garments be used with this process. In some situations brighter fabric colors such as purple, royal and kelly green are not compatible with light on dark printing because they do not fully discharge.

A PVC or acrylic and liquid plasticizer ink system plastisol creates a durable surface film on the fabric. Although not as soft as water-based printing plastisol is far more versatile and when used intelligently can create a variety of desired effects. 4 color process, simulated process and metallic are all based on the plastisol ink system. We take care to minimize our footprint on the environment by using phthalates and PVC free inks when possible.

A plastisol additive that allows inks to adhere to waterproof nylon materials such as jackets and bags. Keep in mind that the temperatures needed to cure plastisol can often exceed the heat exposure recommended for treated synthetic materials, this results in having to flash cure some prints that use nylabond.

With semi-transparent plastisol inks four color process uses halftones of CMYK to create a photo-realistic print process. As a subtractive color system CMYK must be printed over a white substrate. Although white garments are ideal colored garments are compatible with this system when a white baseplate is printed under the graphic silhouette. Substrate (printing), the base material that images will be printed onto.

Much like 4 color process simulated process uses halftones to represent varied shades of a print color. However unlike 4 color process it uses solid opaque inks making it more compatible with darker garment colors.

Available in an array of colors metallics are plastisol based inks with reflective particles that create a chrome or gold like finish. Because these inks generally have a high viscosity a low mesh screen is required to print them making for a thicker ink deposit.

A plastisol ink that uses phosphorus to store surrounding light and then illuminates it in the dark. This ink is generally transparent and can be overprinted on other print colors. It glows a light green.

Fabrics that contain high amounts of synthetic fibers releases their dye when heated causing dye migration between the garment and the screen printing ink. Specially formulated poly inks are required to preserve the intended print color.

We believe that know how is what sets The Foundry Print Shop apart. Evolving with current technology while maintaining a handmade feel, finding solutions to difficult and new situations. Stoked customers and creative products with purpose.

Custom Patches and Woven Labels

To create patches and woven labels we’ll need your art in vector format, if that file doesn’t exist we can generate it for you. Pricing on woven labels and patches varies widely based on complexity and size. In general patches have a 100 units minimum at cost $3 each where woven labels have a 200 unit minimum and cost roughly $0.75 each. The best way to proceed with these type projects is to submit you art and let us know what kind of application you’d like to use the labels on, we’ll provide you with best case scenarios, provide mockups and set the files up for production.

Shop Provided Garments

Letting us provide the garments for your print project is an ideal way to assure compatibility between garment and print process. It’s also a great way to save some coin by taking advantage of our negotiated wholesale contracts with all the best vendors in the garment industry. On occasions we’ll take customer provided garments but for many reasons we prefer not to. Sourced Garments 101

Common Fabric Types

Different fabrics require different print processes.

Cotton is ideal for screen printing because it deforms less than synthetic fibers such as polyester, nylon and acrylic when exposed to the heat needed to cure screen printing inks. It is also the only fabric type that is fully compatible with water-based discharge printing.

Blend fabrics consist of cotton and other synthetic fibers such as polyester, acrylic or nylon. It is recommended that only plastisol screen printing systems be used on poly blend fabrics because the synthetic fibers use colorfast dyes that will not discharge. Some blends are more discharge compatible than others but testing should always be done before production.

Plastisol is the only screen printing ink system compatible with nylon and other waterproof fabrics. Nylabond additive is used to bond the plastisol to the nylon for a more durable and washable print. Because the melting temperature of nylon is close to the the curing point of plastisol ink some nylon prints must be manually flash cured, however our natural gas textile dryer is effective in most situations.

Garments that have 100% synthetic content are often referred to as performance fabrics because of their ability to wick moisture and dry quickly. Due to their hydrophobic nature only plastisol inks should be used to screen print these fabrics. The high amount of synthetic fibers and colorfast dyes require specially formulated inks to prevent dye migration from the garment to the screen printing ink.

With so many fabrics on the market we customize every job to the garment being printed. If customers choose to provide their own garments we strongly suggest they consult with our staff before purchasing them.

Contract Art

While most art separations and file preparations are included in our set up fees we do offer a variety of art and design service for hire. Ranging from digitizing existing art to concept and completion. Contract art and design work is delivered digitized and finished for screen printing and use with other applications such as stickers and signage. We keep a cloud archive of all contract art and printing information so future reproduction is simple and fast.

Art Submission

For optimal print quality please submit your art either in vector format or as a 300DPI PDF, PSD, TIFF or JPG. If possible submit your art flattened and at size, include a detailed description of dimensions and desired print placement. Screen colors vary from monitor to monitor so if you need exact pantones please submit the PMS numbers from the coated book with your art. Do not submit your art pre separated.

Minimum Orders

Establishing and completing a project draws on assets from multiple departments within our business. In order to guarantee quality and accuracy, we have a 50 unit minimum on all contract programs. Please feel free to inquire about exceptions. Learn more about placing an order here!

Print and Embroidery Pricing

To keep from overloading this page with a bunch of numbers and tables, our pricing is on a separate page.

View Pricing