Custom Apparel Startups

Episode 204 - Merch People Actually Wear ( Next Level Apparel)

EPISODE 204 - MERCH PEOPLE ACTUALLY WEAR ( NEXT LEVEL APPAREL) What’s the difference between a shirt people wear to brunch and one they use to wash their car? That’s exactly what Marc Vila from ColDesi tackles in this episode of the CAS Podcast, joined by Melissa Commanday from Next Level Apparel. It’s a deep, no-fluff dive into why the quality of your blank apparel can make or break your brand, your print quality, and your customer retention. This episode is for you if: * You’re tired of selling shirts that don’t get worn * You’ve ever had a customer disappear without complaining — and don’t know why * You want to charge more for your work but can’t justify it with cheap blanks * You’ve invested in great printing equipment and still wonder why your output looks average Here’s what you’ll take away: 👕 Why “freebie-quality” blanks ruin premium designs: No matter how good your artwork or printer is, cheap shirts kill the final product. Marc breaks down how using low-end blanks leads to poor wash performance, bad drape, and print issues — all of which your customer blames on you. 💰 Cost-per-wear logic that boosts your margins: Melissa explains why premium shirts — even if they cost more up front — lead to repeat wears, brand visibility, and more referrals. That $1 difference per shirt? It’s likely your most profitable upgrade. 📉 The silent killer of small business growth: Not all unhappy customers complain. Many just never order again. Learn how to gather meaningful feedback and turn “meh” into loyalty. 🎯 Real talk on rebranding and customer perception: Want your brand to be taken seriously? Then the tearaway tags, soft fabric, and retail-level fit of your blanks matter. Whether it’s your own brand or a client’s, people judge the final piece — not the price sheet. 👚How better blanks = easier selling: If your customers wear the shirts proudly, they become walking billboards. Marc shares how a personal trainer literally gained new clients just by wearing a well-fitted branded tee. If you’re a print shop, designer, or brand selling merch — and you’ve been choosing your blanks based on what’s cheapest on the distributor site that day — this episode will challenge that thinking hard. Because shirts are more than just products. They're emotional. They're identity. They're walking reviews. Listen now if you're ready to stop selling forgettable merch — and start delivering apparel people actually love.

Episode 203 - How to Compete in a Crowded DTF Market

EPISODE 203 - HOW TO COMPETE IN A CROWDED DTF MARKET INTRO: THE SHOP STRUGGLE * DTF is booming and more businesses are jumping in. * DTF is much easier than older methods like screen printing. * Barrier to entry is lower with 'production friendly' equipment under $15k. * Full-Digital Apparel that looks, feels and washes great is 'easy' to make. * If you're feeling squeezed on price, overwhelmed by competition, or stuck on how to grow this episode is for you. WHY IT FEELS CROWDED * Custom t-shirt businesses are more common than even just a decade ago. * People have a 'friend' or 'cousin' with a cricut. * Customer expectations are all over the place a "Why is this shirt $30 when the guy down the street sells it for $15?". * Social media makes everyone look busy, even if they aren't making money. THE GOOD NEWS * Just because everyone's cousin makes shirts, doesnt mean they are good at it. * Most 'side-hustlers' give up or cannot deliver. * The business isnt 'easy' so YOU putting in the work will be around when others won't. * The barrier to entry to be profitable is still high enough that its not for everyone. * You can still produce a high-quality custom logo apparel for the same price or cheaper than stores sell blank apparel. AVOID COMMON TRAPS * Racing to the bottom on price. * You will NEVER be the cheapest. "There is hardly anything in this world that some man cannot make a little worse and sell a little cheaper." * Undercharging because they don't know how to break down costs and margins. * Know your numbers! * Consider other costs - website, accounting software, credit card fees. * No Systems in place to make sure your business runs well * No workflows * No pricing structure * No Schedules * No delegation * No CRM * Trying to do it all: artwork, printing, packaging, selling - without delegation or efficiency. COMPETING THE SMART WAY * Find Your Differentiator: Custom designs? Rush jobs? Better garments? Customer service? Find 1-3 core differentiators and talk about them all the time. * Find Your Niche What is your ideal customer or product? Push towards that and spend less time trying to compete beyond. * Charge What You're Worth: Because of the above, you can (and should) charge more than others. * Tighten Production: Tips to streamline (pre-press setups, batching jobs, designated work zones). * Less mistakes * Faster delivery * Less waste * Customer Experience * Personal delivery * Handwritten thank yous * Reorder reminders * Birthday / Anniversary GROWING IN A CROWDED SPACE * Don't be Amazon / Walmart You can't beat the lowest price, but you can offer the best experience / quality. * People will want to buy from YOU / Your Business... because you are not the big business. * Get Referrals Working * Script for asking for referrals * Remind people again * Give/Get program * Leverage What You Already Have * Upsells / bundled product * Be the best on the block * You would be surprised on how many people havent truly mastered their craft, be a master. Experiment, practice, play, learn. * Invest in an Efficiency (repeat): Set goals for single efficiencies you can invest in (even if it's small.) * Additional heat presses * Accounting software * CRM * Ecom Store FINAL THOUGHTS: THERE'S STILL ROOM! * You don't need to be the best at everything, just the most dialed-in for your customers. * Think efficient and excellent, not big and chaotic. * You don't need to be the master of an entire catalog of products, just be fantastic at a handful. * If you are struggling to compete with lower priced competitors, consider changing how to are getting your business or what you sell. * Only offer premium quality apparel * Look for a niche or type of customer that is going to be less price concerned. * Purchase apparel from the 'cheap' competition to see how you can offer a better product (and sell against that.) Challenge: What's one thing you can fix in your pricing or workflow this week?

Episode 202 - Choosing the Right DTF Printer

In this episode we're diving deep into one of the most important decisions in DTF printing: choosing the right DTF printer. Whether you're just starting out or scaling up a serious production setup, the gear you choose can make or break your workflow, quality, and profits. We'll break down the different printer types and talk about the real-world usage of each. We're also sharing insider tips on what to avoid, and what else you'll need beyond just the printer to actually succeed with DTF. At the end of the episode we have specific advice tailored for beginners looking to start smart, and pros aiming to optimize or expand. UNDERSTANDING PRINTER TYPES AND KEY FEATURES PRINT WIDTH OPTIONS * Letter / A3 Sheet (12-13") * Small format sheets for basic transfers * 12" * Ideal entry into roll-to-roll printing * 24 - 30" * Faster production for professional setups INK SYSTEMS * Bulk Ink Systems * Lower ink costs * Requires maintenance knowledge * Cartridge Systems * More reliable for light to medium use * Higher cost per print * White Ink Circulation * Prevents settling and clogging in pro setups INTEGRATED VS. MODULAR SETUPS * All-in-One Printers * Includes printer, shaker, oven in one unit * Separate Components * Greater flexibility for upgrades and maintenance BUDGET CONSIDERATIONS ENTRY-LEVEL SETUPS * Desktop Printer + Manual Shaker * Pros: Low upfront cost, real DTF transfers possible * Cons: 10+ minutes per transfer, inconsistent quality, no white ink circulation Verdict: Not recommended for production-focused businesses. MID-TIER OPTIONS * A3 Size Sheet Printers * Pros: Compact size, low cost * Cons: Slow production, not automated * Compact Roll-to-Roll Systems * Pros: Automated, less manual labor, better consistency * Cons: Higher investment, learning curve Verdict: Roll-to-roll is generally the winner at this tier. PRO-GRADE OPTIONS * 24"+ Wide Format Printers * Pros: White ink circulation, fully automated, designed for production and ROI * Cons: Highest investment, requires significant space and power Verdict: Bigger and faster is almost always better for serious DTF operations. ESSENTIAL ADDITIONAL EQUIPMENT * Heat press(es) * Powder extractor or filtration system * Emergency kit for clogs and maintenance * Startup consumables and supplies RELIABILITY AND MAINTENANCE DAILY UPKEEP * Follow manufacturer guidelines * Maintain temperature: 60°F – 80°F * Maintain humidity: 50% – 70% * Keep a dust-free environment COMMON FAILURE POINTS * Printheads: Especially with white ink; discuss preventative maintenance with your vendor * Powder Adhesive Curing: Adjust time and temp based on weather and material WHERE TO BUY AND WHAT TO AVOID CHOOSING VENDORS * Trusted brands with proven track records * Who supports you post-purchase? KEY QUESTIONS TO ASK * How long have you been in business? * What is the warranty? * How many printers/customers do you have? * Can I see a sample print? * Can we do a live or virtual demo? EVALUATING TEST PRINTS * Feel and stretch tests * Wash tests * Feedback from existing customers or focus groups FOR BEGINNERS * Look for simplicity, strong support, and learning resources * Avoid shiny object syndrome; focus on reliability * Starter kits and bundles can help but verify quality * Remember: It's better to over-invest in equipment than under-invest. FOR PROS * Buy based on current production plus growth goals * Don't expect to abandon other print technologies immediately * Set client expectations if changing print methods * Educate clients on color differences between spot and process printing * Upsell expanded color options to lock in clients * Train staff thoroughly for day-to-day operational changes Choosing the right DTF printer setup comes down to understanding your production goals, budget, and willingness to maintain the equipment properly. Whether you're starting with an entry-level setup to learn the process or investing in a full pro-grade system to drive your business forward, focus on reliability, vendor support, and scalability. The right choice will save you time, reduce frustration, and allow you to confidently produce high-quality transfers for your customers. Be sure to check out ColDesi.com [https://coldesi.com/] and learn more about how Direct to Film printing can help your business thrive.

Episode 201 - Grow Your Business with Direct Mail - Featuring Taylor

In this episode of the Custom Apparel Startups Podcast, host Marc Vila is joined by Michael Palme and Austin Gordon from Taylor to discuss how direct mail can be a game-changer for custom apparel, sign, and promotional product businesses. While digital marketing gets a lot of attention, direct mail remains a powerful and underutilized tool for targeting new customers, retaining existing clients, and cutting through the clutter of online ads. Michael and Austin break down how direct mail works, how to effectively use data to reach the right audience, and how you can integrate it with digital advertising for even greater results. Whether you’re a startup looking to establish your brand or an established business aiming for the next level, this episode will give you practical strategies to expand your reach and increase sales. Topics Covered in This Episode: ✅ Why direct mail still works in a digital world ✅ How to use data to target the perfect audience for your business ✅ The cost of direct mail—how much should you budget? ✅ How to track results and measure ROI ✅ The best types of mail pieces for apparel and sign businesses ✅ Combining direct mail with digital ads for maximum impact ✅ How to start a direct mail campaign—step-by-step guide ✅ Common mistakes to avoid when using direct mail marketing Listen now and learn how to use direct mail to take your business to the next level! 📩 Have questions or want to connect? email us at marketing@coldesi.com [marketing@coldesi.com].

Episode 200 - The Secret to Selling Tshirts Right Away

In this episode, we dive into the exciting world of entrepreneurial spirit with a focus on launching a custom t-shirt business. We'll explore a practical, step-by-step guide designed for beginners eager to make a mark in the t-shirt industry, even with little to no prior experience. Whether you've dabbled in t-shirt sales or are just curious about this creative venture, this episode is your gateway to starting a successful side hustle immediately. We’ll dissect a downloadable document that outlines six actionable strategies that have proven successful for startups across the country. From leveraging your personal network to making smart use of social media and local community engagement, we cover all the bases to ensure you're well-equipped to start generating business right away. Join us as we reveal the secrets to turning referrals into sales, using everyday interactions as promotional opportunities, and why something as simple as a well-timed text message or a social media post can be incredibly effective. If you're ready to start making money by selling custom t-shirts, this episode will provide you with the knowledge and inspiration to hit the ground running. Tune in to transform these insights into action and start achieving your dreams today!