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by Custom Apparel Startups
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- Jan 20, 20261h 7m
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 wornYou’ve ever had a customer disappear without complaining — and don’t know whyYou want to charge more for your work but can’t justify it with cheap blanksYou’ve invested in great printing equipment and still wonder why your output looks averageHere’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.
- Aug 15, 202547 min
Episode 203 - How to Compete in a Crowded DTF Market
Episode 203 - How to Compete in a Crowded DTF MarketIntro: The Shop StruggleDTF 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 CrowdedCustom 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 NewsJust 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 TrapsRacing 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 wellNo workflowsNo pricing structureNo SchedulesNo delegationNo CRMTrying to do it all: artwork, printing, packaging, selling - without delegation or efficiency.Competing the Smart WayFind 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 mistakesFaster deliveryLess wasteCustomer ExperiencePersonal deliveryHandwritten thank yousReorder remindersBirthday / AnniversaryGrowing in a Crowded SpaceDon'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 WorkingScript for asking for referralsRemind people againGive/Get programLeverage What You Already HaveUpsells / bundled productBe the best on the blockYou 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 pressesAccounting softwareCRMEcom StoreFinal 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 apparelLook 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?
- Jul 8, 202556 min
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 OptionsLetter / A3 Sheet (12-13")Small format sheets for basic transfers12"Ideal entry into roll-to-roll printing24 - 30"Faster production for professional setupsInk SystemsBulk Ink SystemsLower ink costsRequires maintenance knowledgeCartridge SystemsMore reliable for light to medium useHigher cost per printWhite Ink CirculationPrevents settling and clogging in pro setupsIntegrated vs. Modular SetupsAll-in-One PrintersIncludes printer, shaker, oven in one unitSeparate ComponentsGreater flexibility for upgrades and maintenanceBudget Considerations Entry-Level SetupsDesktop Printer + Manual ShakerPros: Low upfront cost, real DTF transfers possibleCons: 10+ minutes per transfer, inconsistent quality, no white ink circulationVerdict: Not recommended for production-focused businesses.Mid-Tier OptionsA3 Size Sheet PrintersPros: Compact size, low costCons: Slow production, not automatedCompact Roll-to-Roll SystemsPros: Automated, less manual labor, better consistencyCons: Higher investment, learning curveVerdict: Roll-to-roll is generally the winner at this tier.Pro-Grade Options24"+ Wide Format PrintersPros: White ink circulation, fully automated, designed for production and ROICons: Highest investment, requires significant space and powerVerdict: Bigger and faster is almost always better for serious DTF operations.Essential Additional EquipmentHeat press(es)Powder extractor or filtration systemEmergency kit for clogs and maintenanceStartup consumables and suppliesReliability and Maintenance Daily UpkeepFollow manufacturer guidelinesMaintain temperature: 60°F – 80°FMaintain humidity: 50% – 70%Keep a dust-free environmentCommon Failure PointsPrintheads: Especially with white ink; discuss preventative maintenance with your vendorPowder Adhesive Curing: Adjust time and temp based on weather and materialWhere to Buy and What to Avoid Choosing VendorsTrusted brands with proven track recordsWho supports you post-purchase?Key Questions to AskHow 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 PrintsFeel and stretch testsWash testsFeedback from existing customers or focus groupsFor BeginnersLook for simplicity, strong support, and learning resourcesAvoid shiny object syndrome; focus on reliabilityStarter kits and bundles can help but verify qualityRemember: It's better to over-invest in equipment than under-invest.For ProsBuy based on current production plus growth goalsDon't expect to abandon other print technologies immediatelySet client expectations if changing print methodsEducate clients on color differences between spot and process printingUpsell expanded color options to lock in clientsTrain staff thoroughly for day-to-day operational changesChoosing the right DTF printer setup co
- Feb 18, 202552 min
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 marketingListen 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.
- Jun 20, 202440 min
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!
- Jun 12, 20241h 0m
Episode 199 - Growing A Customization Business
In this insightful episode, we sit down with Trevor and Trent Walden, the pioneering duo behind the Walden Bros., an Alaskan t-shirt shop specializing in Direct to Film (DTF) printing and embroidery. As they navigate the intricacies of the customization industry, the Walden brothers share their journey of transforming an idea to a successful family business.Key Discussion Points:Taking ideas and going for it: The Walden Bros. recount their initial days, emphasizing the importance of good ideas, family and hard work.Taking Risks: Trevor and Trent delve into early wins and losses that helped make the business it is today.Building a Brand: The brothers explain their approach to creating a strong brand identity that resonates with their customers.Customer Engagement: They highlight strategies for engaging customers and personalizing experiences to foster loyalty and repeat business.Challenges and Triumphs: The conversation also covers hurdles they've faced, how they've overcome them, and the lessons learned along the way.This episode not only provides a behind-the-scenes look at running a successful customization business but also serves as a guide for entrepreneurs eager to carve out their own niche in the competitive industry of bespoke products. Join us as Trevor and Trent Walden lay down the blueprint for aspiring customizers looking to expand their horizons.
- Jun 5, 202452 min
Episode 198 - How To Convert A Screen Printing Shop To DTF
In this episode, we delve into the exciting world of Direct to Film (DTF) printing and how you can transition your screen-printing shop to embrace this innovative technology. We'll start by explaining what DTF printing is and why it's gaining popularity. Next, we'll break down the investment costs involved, giving you a clear picture of what to expect financially.We'll explore the wide variety of materials you can print on with DTF and detail the essential equipment you'll need to get started. Wondering if you should keep your screen-printing machines?We'll weigh the pros and cons to help you make an informed decision.Additionally, we'll discuss other important factors to consider during the transition, provide insights into the current DTF market, and guide you on how to obtain a sample DTF print to see the quality for yourself. Whether you're a seasoned screen-printer or new to the industry, this episode is packed with valuable information to help you navigate the switch to DTF printing. Tune in and learn how to expand your printing capabilities and stay ahead in the competitive market.
- May 23, 202459 min
Episode 197 - DTF vs Screenprinting
In this insightful episode of Custom Apparel Startups, we welcome Howard Potter back to discuss the nuances between Direct to Film (DTF) printing and traditional Screen Printing. With his deep-rooted knowledge from A&P Master Images, Howard breaks down the pros and cons of each technology, helping entrepreneurs make informed decisions tailored to their business needs.The conversation begins with an overview of each printing method’s technical demands and operational scopes. Howard elaborates on the initial investment costs, ease of operation, and scalability potential of DTF and Screen Printing, giving listeners a comprehensive comparison.Highlighting key factors like print quality, production speed, and cost-effectiveness, Howard shares his firsthand experiences with both methods. He discusses how DTF offers flexibility and precision with lower setup times, making it ideal for small to medium runs.Conversely, Screen Printing is celebrated for its economic benefits in large batch productions and its lasting print quality.Further, Howard addresses common misconceptions and challenges associated with each method, such as the steep learning curve of Screen Printing and the upfront costs associated with transitioning to or starting with DTF.Listeners will come away with a clear understanding of which printing method might best suit their current operations and future growth plans, armed with Howard Potter’s practical advice and industry insights. Whether you're a startup in the apparel industry or looking to expand your existing setup, this episode serves as an essential guide to mastering these popular printing techniques.
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About Custom Apparel Startups
The Custom Apparel Startups podcast was started simply because we love both the apparel decorating business and the idea that almost anyone, with a small investment and a little dedication, cannot only start their own business but thrive! Our goal in starting CAS is to help educate apparel entrepreneurs about the business of the business, something often overlooked by people with an idea and a budget, but no business plan or experience behind them. We’ll be talking with the biggest names in the apparel decorating about things that are interesting and useful for all of you. Below are just a few topics we’ll be covering: Marketing Ideas Finance and Taxes Social Media eCommerce and Shopping Cart Software Pricing your work Managing inventory Equipment and Software Uses
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