A Guide to our Custom Printing Options

Custom Caps Canada takes pride in offering a wide array of printing options for custom hats, hoodies, sweatshirts, and jackets. Each printing method comes with its own unique set of advantages and limitations, making it crucial to select the right method tailored to your specific needs. Our team of experts is always ready to guide you, and we will suggest better alternatives if your chosen print option isn't the ideal fit. While some of these options are readily available, others can be provided upon request. In this comprehensive guide, we will delve into the details of each printing option we offer, helping you make an informed decision for your custom apparel needs. Whether you're aiming for durability, complexity, or a unique aesthetic, we've got you covered.

In this comprehensive guide, we will delve into the details of each printing option we offer, helping you make an informed decision for your custom apparel needs. Whether you're aiming for durability, complexity, or a unique aesthetic, we've got you covered.

Table of Contents

1. Embroidery
2. DTF Transfer
3. 3D Puff Embroidery
4. Embroidered Patches
5. Perma-twill Patches
6. Woven Patches
7. Leather Patches
8. Sublimated Patches
9. Rubber Patches

1. Embroidery

Embroidery is our primary embellishment method, and it involves using commercial embroidery machines and premium digitizing to ensure high-quality results. This method is best suited for low to medium complexity designs with text no smaller than 4mm. While our recommended minimum letter size is 6mm high with columns at least 1mm thick, smaller sizes can be achieved at the cost of some quality.

Pros:

• Durable and Long-lasting: Embroidery offers exceptional durability, ensuring your designs stand the test of time.
• Versatile Designs: It can be used to create a variety of designs, making it suitable for logos, text, and intricate patterns.
• High-quality Finish: The finished product boasts a professional and polished appearance.
• No Setup Charges: There are no setup charges involved.
• No Minimum Order Limit: Whether you need one piece or hundreds, embroidery accommodates orders of all sizes.

Cons:

• Not Suitable for Complex Designs: Embroidery is not ideal for complex designs and small text.
• Additional Stitch Charges: Designs with over 10,000 stitches may incur additional charges at $1 per 100 stitches.

2. DTF Transfer

DTF, or Direct-to-Film, is a modern printing method gaining popularity rapidly. It is a digital printing process that transfers a printed film onto the fabric of the garment.

Pros:

• Fast and Efficient: DTF is known for its speed and efficiency in the printing process.
• Complex Designs and Gradients: It can be used to print full-color high-complexity designs and gradients.
• No Background Fill Required: DTF doesn't require a background fill, resulting in more design flexibility.
• No Minimum Order Quantity: You can order any quantity you desire.
• No Setup Charges: There are no setup charges involved.

Cons:

• Durability: It may not be as durable as embroidery. On average they last upto 50 washes.
• Not suitable for most hats: Doesnt work well with the seam and structured hats.
• Fabric Compatibility: It may not be ideal for certain types of fabric.

3. 3D Puff Embroidery

3D puff embroidery employs foam inside the design, creating a raised 3D effect. This option is available exclusively for hats.

Pros:

• Unique and Eye-catching:The 3D effect provides a unique and eye-catching premium look.
• Durable:Like traditional embroidery, it is durable and long-lasting.

Cons:

• Limited to Simple Designs: Works best with simple designs.
• Column Size Restrictions: Each column in the design should be between 3-15mm.
• Expensive for Small Quantities: It can be cost-prohibitive for small orders.

4. Embroidered Patches

Embroidered patches involve embroidering your design on a twill fabric, which is then heat-pressed onto the garment. This option is ideal for medium complexity designs, especially for hats, and patches can be of any shape.

Pros:

• High-quality Finish: It delivers a high-quality finish with a premium look.
• Durability: Embroidered patches are durable and long-lasting.
• Suitable for Medium Complex Designs: Works well with medium complex designs.

Cons:

• Turnaround Time: Expect a turnaround time of 15-18 business days.
• Setup Fees and Per Patch Charges: Embroidered patches come with a setup fee and per-patch charges.
• Solid Background: The patches have a solid background.

5. Perma-twill Patches

Perma-twill is a synthetic material that we print on, laser cut, and then adhere. It creates a patch-like look and is available for quantities of 20 or more. For orders of less than 20 units, there is a $45.00 setup charge.

Pros:

• Durability: Perma-twill patches are durable and long-lasting.
• Complex Designs: Works well with complex designs.
• Cost-effective: Cheap for 20 or more units. No per-unit charges.

Cons:

• Setup Fee for Small Orders: A setup fee applies to orders of less than 20 units.
• Texture: Printing on twill fabric adds some noise to the design.
  
  

6. Woven Patches

Woven patches offer a high-end printing option that creates a sharp and professional look with very thin threads. They are often used for corporate uniforms and garments that require a pristine appearance.

Pros:

• High-quality Finish: Woven patches deliver a sharp and professional appearance.
• Durability: They are durable and long-lasting.
• Complex Designs and Small Letters: Ideal for complex designs and small lettering.

Cons:

• Setup Fee for Small Orders: A setup fee applies to orders of less than 50 units plus per patch charges.

7. Leather Patches

Leather patches provide a unique and stylish printing option that adds a touch of luxury to your garments. They are available in various colors and styles and can be debossed or embossed with your logo, text, or images.

Pros:

• Unique and Stylish Look: Leather patches offer a unique and stylish aesthetic.
• Durability: They are durable and long-lasting.
• Versatile Designs: Suitable for a variety of design choices.

Cons:

• Minimum Order Quantity: Leather patches are only available for orders of 20 or more units.
• No Design Colours: Since the designs are laser engraved, there can be only one dark colour.

8. Sublimated Patches

Sublimated patches involve a digital printing process that transfers a design onto a piece of fabric. They are an excellent option for garments made of synthetic fabrics, such as polyester and nylon.

Pros:

• Wide Range of Colors and Designs: Sublimated patches can reproduce a wide range of colors and intricate, complex designs.
• Ideal for Synthetic Fabrics: They are well-suited for synthetic fabrics.
• Durability: Sublimated patches are durable and long-lasting.

Cons:

• Setup Fee Plus Per Unit Charges: Has a setup fee applies to orders of less than 50 units.

9. Rubber Patches

Rubber patches are a durable and weatherproof printing option ideal for outdoor garments and equipment. They are available in various colors and styles and can be debossed or embossed with your logo, text, or images.

Pros:

• Durable and Weatherproof: Rubber patches are designed to withstand harsh outdoor conditions.
• Versatile Designs: Can be used to create a variety of designs.

Cons:

• Setup Fee: There is a setup fee of $100.

If you are looking for another print option, we may be able to get it for you. Feel free to send us a message with the details to disucss and create amazing custom products for your next project