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Garment / Apparel Division

Currently in the USA there are about 80 major brands that market millions of dollars on clothing or apparel accessories and another 200 or so recognized as “Major Brands”. Total Custom Solutions has best line pricing relationships with over 130 of these companies and a working connection with just about all of the others. We also work closely with over 70 international and Asian manufacturers who private label for most of the world. Of the common USA offered products we have immediate inventory to over 300,000 unique garments from these 130 brands. With 5-40 color choices in each and 4-10 size options the net total unique items in our quick ship offerings is somewhere around 15 million.

We know of no other house that has as much available inventory as we do. Working closely with the mills, brands and their warehouses we do not run out of stock unless literally none exists anywhere in the USA. We are constantly monitoring prices with state of the art data base management sytems and inventory control software so we are able to deliver the most current and lowest prices in first run quality garments from all of these brands.

We do NOT stock seconds, flawed, stained or sub-standard garments ever. However, if your needs are specific in that area for some reason we can shop it for you. However our best line pricing on first rate goods should allow you to never have to sell or use less than 1st quality garments. All Embellishments including yet not limited to the following list are available on any and all of our merchandise within reason.

Silk Screen up to 8 colors – Screen printing, also known as serigraphy, is one of the oldest print methods. It has its origins some 3000+ years ago and was eventually patented in the early 1900 in Manchester England. It is one of the most effective ways to create an image on paper, fabric or some other object bypressing ink through a screen with areas blocked off by a stencil. The technique is used both for making fine art prints and for commercial applications, such as printing a company’s logo on coffee mugs or t-shirts. It is quite often the most cost efficient ways to get your design out there when you are printing in moderate volumes. However, in very small quantities – the set up costs associated with the film prep and screen creation can make other options more favorable.

Embroidery – It is needlework used to enrich textile fabrics, leather, as a form of ornamentation of fabric with fanciful decorative details. It is often used to apply a branded logo and tag line to better garments. Custom designs require what is referred to as a digitized image which is a computerized set of instructions which tell the embroidery machine exactly how and where to stitch the design. It can be applied to a stand-alone piece of fabric as an applique for later use or stitched directly onto the garment.

Direct Full Color Imprint – DTG is a relatively new fabric printing method that prints an image directly onto a garment or fabric through what is essentially a modified version of a traditional inkjet printer. Think of a regular inkjet printer which has been modified to “accept” garments instead of paper. The ink is printed directly onto fabric which results in exceptional “hand” (common term in the industry referring to how a garment feels once the image or design has been printed on it), and offers more flexibility than screen printing in terms of color variation and turn-around time (especially for smaller orders). As these inks and dyes continue to evolve DTG is proving to be a durable long wearing solution where full color is desired. It can also be printed onto a heat transfer vinyl and applied to the garment via a heat transfer press or a household iron for later application.

All Over Full Color Dye Sublimation – Sublimation dyes are printed directly onto a bolt of fabric, OR finished garments OR onto a transfer medium. Each is done with a specially prepared inkjet printer. Thereafter, those dyes are then transferred from the medium to an object or garment under the heat and pressure delivered by a commercial heat press. Sublimation works best on garments made of polyester, plastic or ceramics and is widely used throughout the garment and promotional product industries. When the heat and pressure are applied, the dye on the transfer medium sublimates, or becomes a gas, and is then absorbed into the polyester itself;the print is actually a part of the garment/coating. It doesn’t fade easily, wear, or have any texture or weight. This method is best used for larger volume runs or where all over designs are used. Most clothing and all full color printed promotional products that are not printed DTG with an allover design which is not an actual part of the weave using different collared threads are printed in this method. It is also used in branded apparel and as equipment and technology are quickly improving it is becoming more and more popular for branded apparel.

Heat Transfers – Full Color digital printing using a wide assortment of dyes, paints, inks or Plastisol inks used in silk screen printing and even glitter, rhinestone and other design elements are printed onto a transfer paper or vinyl for application later through the use of heat and pressure. If applied correctly, proper heat and time and pressure, these designs will last as long as the garment. Heat transfers have become widely accepted as a high value solution especially where low quantity solutions are needed or you intend to add the finished design to various different garments or mediums later. Specialty heat transfer equipment shapes make it possible to add heat transfers to a wide assortment of promotional products, hats, ceramics, tiles, tote bags etc.

Appliques & Patches – Most commonly, embroidery stitched designs are created on a base fabric and then cut to shape which can either be applied via a heat transfer press if heat sensitive glues are applied to the backing fabric OR they can be hand sewn onto the garments. Many times for effect, various felted fabrics, vinyls, leathers or a combination of textiles and even padding are used to add depth and dimension to athletic sport team spirit clothing as well as embroidered appliques & patches. Especially popular in branded logo wear, police, fire and rescue patches.

Custom & Stock Rhinestone Designs – These are most often custom, creative combinations of rhinestones laid out in a pattern or design and added to a garment for its glamorous and decorative value as well as providing a powerful branded logo to your garments. It is sometimes part of a mixed media solution and is often applied over dye sublimation for a unique and highly sought after look. Most rhinestone designs are applied by a heat transfer press. And can be ordered in smaller quantities.

Custom & Stock Glitter Designs – Glitter is becoming more widely used in a lot of garments and can be added in addition to or as part of the silk screen or heat transfer processes. In some cases they can be applied directly to a garment with special sprays or additives. Glitter does only reasonably durable and special care is needed in washing to preserve the glitter. It can be added to small or larger run orders.

Small Run Silk Screen Custom Transfers – Silk screen Plastisol inks can be machine applied directly to a transfer paper or vinyl and then heat applied later to a wide variety of apparel, hats, and promotional products using the right equipment. Many argue that the quality and consistency and precision of this form of silk screen printing is much higher quality and will not tend to crack or peel over time as easily as traditional silk screen printed items can due to the precision of the applied heat and pressure. In small quantities it tends to be a very cost effective solution as the cost of film and screen print screen creations are less. However, on larger runs tradition screen printing proves to still be the most economical print solution. However, if precision silk screen designs are important than this is the best method. It is not extremely effective in designs with more than 6-8 colors or where photorealism is desired.

Scented Ink Silk Screen – just as it sounds – a scent is added to the Plastisol inks which will fade over time. However, it adds a delightful surprise to the garment and if scent is part of your brand or you are trying to appeal to the younger generation then stink inks or scented ink silk screening might be for you. There are many stock scents that are reasonable in cost while custom scents are a bit more pricey and are best left to larger print runs.

Puff Ink Silk Screen – Puff ink is applied either by hand or a special Plastisol ink is used in the silk screen process that expands as it is cured and provides a level of 3 dimensional effect to the garment. It also has a hand or feel that many like. It has some limitations and additional care is needed to help it last as it is not quite as durable. However, it is highly popular regardless. Best used as an accent or outline to most designs or branded logos. Puff Inks can be ordered in modest quantities.

Discharge Ink on 100% Cotton garments – While the discharge process can be used on some blends it will not create a consistent print finish which is why it is recommended to be used on only 100% cotton fabrics. Discharge ink is applied to a colored cotton fabric through a silk screen which actually releases the color in a similar yet not damaging way as bleach does. Then it is replaced with another dye via the same method. What makes this an exciting print solution is that it literally becomes part of the fabric and adds no other coatings or textures so the hand or feel is identical to the rest of the garment and will last as long as the garment lasts. This method tends to be best suited to muted or soft colors and an exact color match is not to be expected as the discharge process does not get the cotton back to perfect white and the new dyes may not get a 100% saturation or opacity. But the look and feel is spectacular and for 1 color imprinting especially it is becoming an extremely hot commodity. Works great for random designs and decoration or for branded apparel designs. It can easily be combines with traditional silk screen to create a unique dimension. Also would work well with rhinestone designs.

Metallic leaf or Inks – new Plastisol silk screen inks with a metallic finish are quickly being well received in the marketplace. Metallic leaf type finishes can also be applied through a heat press process depending on the look and feel that you are seeking. It can be a great stand-alone look or can be an addition to other mediums and processes.
Vinyl lettering – Most often vinyl lettering is used in athletic sport apparel form names and number or in the professional trades to add individual names to uniforms. It is heat press applied and has very good durability.

Full Color Vinyl transfers – A special white vinyl as used in vinyl lettering is full color imprinted in vibrant colors on colored garment and can be custom trimmed or cut into any shape to match the imprinted design and then applied like a heat transfer. The resolution if printed is fabulous. Most often a 1/16 of an inch of the white is left as a with outline. However for a nominal added cost it can be trimmed away.

All of these methods have unique looks, uses and applications. Not to mention the unlimited possibilities of mixing them up to create a totally unique design on your garments. Not all methods can be added on top of one another but surprisingly with a bit of creativity almost anything is possible.

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