____________________

Registration now open for the 2025 Impressions Expo in Dallas, Texas, Oct. 2-4

Registration is now open for Impressions Expo Dallas, set to take place October 2-4, largest custom decorated apparel event in the South. Not only that, but admission to this year’s Dallas expo is totally FREE OF CHARGE if you get your registration in by June 11. Sign up now to check out the latest on offer from scores of leading equipment, materials and blank apparel suppliers from across the decorated-apparel industry.

____________________

A record-setting Impressions Expo, cutting edge machine embroidery and yet more direct-to-film (DTF) tech

Alas, for those hoping for “less interesting times” following the turmoil of the past few years, the world, for better or worse, remains as “interesting” as ever. That said, the good news as far as the custom decorated-apparel business goes is that there’s just no keeping down the decorators of the world—as was evident at the first two Impressions Expos of 2025, in Long Beach, California, and Atlantic City, New Jersey. And things continue to look goof for the next Impressions Expo of 2025, set to take place in Dallas, Texas, Oct. 2-4.

Save the Date: 2025 Impressions Expo, Dallas, Texas, Oct. 2-4

Here we are fast approaching the mid-point of 2025. Suffice it to say, it’s been quite the year! The good news is the decorated-apparel industry has not only come through the roller coaster ride that has been the past few years, but looks to continue to do so despite the air of economic uncertainty surrounding the present. With that in mind, don’t miss out on the next Impressions Expo of 2025, set to take place Oct. 2-4 in Dallas, Texas.

____________________

Navigating Economic Uncertainty: An Apparel Decorator’s Guide

Between the threat of rising inflation, uncertain economic forecasts and the increasing effects of the on-again-off-again Trump tariffs, businesses across the decorated-apparel industry find themselves in an uncomfortable position. Fortunately, the custom decorated-apparel industry has proven its resilience in the past and is in many ways perfectly positioned for whatever may come in the future.

____________________

Impressions Expo 2024: It’s a Wrap, See you in 2025!

Another Fort Worth Impressions Expo is officially in the books, and what an expo it was, with well north of 3,000 attendees and exhibitors taking part in this year’s event. In addition to the more than 130 exhibiting companies that were on hand (staking out an impressive 14 percent more floor space than in the previous year) the 2024 expo featured crowds and an energy that had to be seen to be fully appreciated. Already looking forward to the 2025 event!

The post 2025 Impressions Expo Dallas Resource Page: Don’t Miss Out! appeared first on Impressions.

Join thousands of other screen printers, embroiderers, heat-press decorators, and equipment, materials and blank apparel suppliers from across the decorated-apparel industry for three days of learning, inspiration and networking. Whether you’re looking to sharpen your skills, grow your business, or discover what’s next in decorated apparel, you’ll find it here.

For complete registration and pricing information, including early bird pricing and pricing for participation in the show’s attendant professional education conference series, click here. As a reminder, for longtime attendees, especially, this is the same annual event that in years past took place in Fort Worth, Texas.

For the latest news and updates on the 2025 Impressions Expo in Dallas, Texas, click here.

The post Registration Now Open for Impressions Expo Dallas 2025: Sign Up FREE OF CHARGE Between Now and June 11! appeared first on Impressions.

Philadelphia, Pennsylvania-based Ninja Transfers, a leader in the custom DTF (direct-to-film) heat transfer industry, has announced the launch of a new service it’s calling, Ninja Print on Demand, a powerful new solution designed to help creators, entrepreneurs and companies of all kinds design, sell and fulfill custom apparel—all without upfront costs or inventory management.

According to Ninja Transfers, with Ninja Print on Demand, “Users can upload their designs, select from a wide range of premium apparel and hardgoods, and have orders automatically printed and blind shipped directly to their customers across the country. The entire process is handled in-house, ensuring professional-grade quality and fast turnaround times.”

Shopify App Complements POD Service’s Efficiencies

In conjunction with its new POD initiative, Ninja Transfers has also launched a free Shopify app, allowing custom apparel decorators to quickly and easily integrate their storefront, start selling and begin generating profits—all without ever touching a product.

“Ninja Print on Demand is the next evolution in our mission to support creators,” said Victor Ilisco, director of business development at Ninja Transfers. “We’ve combined our industry-leading DTF technology with a user-friendly platform that removes the barriers to launching or growing an apparel business or brand.”

To learn more or get started with Ninja Transfers’ new POD option, go to ninjaprintondemand.com. For more on Ninja Transfers and its entire line of products and services, including heat-applied patches, custom DTF transfers, Easy Peel technology, blank apparel and Ninja Printhouse, the company’s custom apparel and promotional products blind-shipping division, visit ninjatransfers.com.

The post Ninja Transfers Launches ‘Ninja Print on Demand’ Service appeared first on Impressions.

As evidence of this fact, look no further than the first two Impressions Expos of 2025 in Long Beach, California, and Atlantic City, New Jersey, with decorators large and small still doing what they do best. As part of this never-say-die attitude, they have not only kept on decorating, but have continued to expand both their product lines and their capacities in general, with a seemingly endless supply of newbies coming into the industry.

Decorated Apparel Industry’s Leading Trade Show

Similarly, on the blanks side, the items on offer continue to improve with respect to everything from comfort and style to the sustainable processes being used to produce them. No longer are consumers willing to settle for any old grungy T-shirt or hoodie. They want quality, comfort and good looks, garments they’re going to want to wear over and over again. And the industry has responded in kind.

In other words, as was the case in 2024, there’s never been a better time to check out the industry’s latest and greatest at the next Impressions Expo of the year, set to take place Oct. 2-4 in Dallas, Texas. As always, the event will also feature an unparalleled assortment of suppliers and hands-on conference sessions, all expressly designed to help you grow your business.

As has been the case with expos past, there will also be a wealth of networking opportunities; T-shirt giveaways for all at the Impressions Expo live screen-printing station; and, of course, Shop Talk powered by Ink Kitchen, with industry veteran Rick Roth, CEO of Mirror Image Inc., interviewing experts from across the of decorated-apparel world. In other words, y’all don’t want to miss out!

For more on all three Impressions Expos, including the events in Long Beach, California, and Atlantic City, New Jersey, click here.

For the latest news and updates [including registration details] on the 2025 Impressions Expo in Fort Worth, Texas, click here.

The post Save the Date: 2025 Impressions Expo, Dallas, Texas, Oct. 2-4 appeared first on Impressions.

The good news is the decorated apparel market continues to grow, with an expected valuation in the United States alone of as much as $20 billion by 2033. The bad news? The custom decorated-apparel sector remains as competitive as ever as well, with creativity and innovation continuing to be the name of the game, the same as in years past. Staying stuck too long may very well result in your falling behind as well.

Equipment, Increased Efficiency

When was the last time you evaluated your equipment lineup? If you’re using outdated machinery, it might be time for an upgrade. New technology allows you to improve production speeds, expand your service offerings and reduce waste.

Depending on the kind of custom apparel decorating you specialize in, branching out/embracing other kinds of decorating technologies can also provide your company with an added edge.

Equipment Upgrades to Consider:

• Direct-to-garment (DTG) Printing: Ideal for high-detail, small-batch orders. Full-color, photo-style designs can be easily created for even the smallest batch orders, in stark contrast to screen-printing with its larger production runs.

• 

  There’s nothing like an automatic screen printing press to boost capacity-assuming it makes sense financially! Photo courtesy of Impressions Expo

  Heat Press Direct-to-transfer (DTF) Printing: Ideal for producing durable designs on multiple materials, including polyester and nylon. Commercial quality entry-level heat presses are affordable and easy to operate. Custom DTF transfers can be easily outsourced to any number of different manufacturers, making the barrier to entry to this decorating technique a minimal one.

• Automated Screen Printing Presses, Accessories: Tackle larger orders while maintaining consistency and quality. Possible upgrades can include everything from a new “auto” to automated screen reclamation systems, screen coating machines, higher-grade exposure units and laser-to-screen (LTS) screen printing systems.

Expand Your Custom Decorating Offerings

Variety is the spice of life, and in custom apparel decoration, offering diverse services can be a great way of attracting a wider customer base. Additional services you might want to consider adding to your skillset include:

1) Custom Embroidery

Great for corporate branding, especially, custom embroidery on polos or hats can generate more business clients. While the barrier to entry remains a challenging one, today’s technology is such that mastering the rudiments of the art of embroidery is much less daunting than in years past. This is an area in which outsourcing your embroidery work to a fellow decorator can also make all the sense in the world.

2) Sublimation Printing

A proven but often overlooked decorating technique among newer decorators, especially, sublimation printing allows for vibrant, full-color designs beyond the typical garment, such as mugs, phone cases and tote bags. Ideal for printing on performance polyester apparel, in particular.

3) Non-apparel Custom Merch

With today’s technology, the lines between apparel decoration and custom-decorated hardgoods is becoming increasingly blurred. It’s a simple jump for heat-press decorators, especially to branch out into mug or water bottle decorating (see “Sublimation Printing” above). Drop-ship merch providers represent viable option for those interested in “testing the waters” in this area as well.

4) Eco-Friendly Decorated Apparel

Sustainability is more than a buzzword. With eco-conscious consumers on the rise, offering organic or recycled fabric options can position your brand as socially responsible while attracting new customers.

Rethink Your Social Media/Marketing Strategy

If “marketing” at your company consists of little more than posting sporadic photos on Instagram, it’s time to think bigger. A targeted, multi-channel strategy can work wonders for engaging both existing and new customers.

Marketing Tips to Adopt:

• Invest in Quality Content

Post behind-the-scenes videos of your printing process, tutorials about garment care or how-to guides on pairing custom apparel with complementary accessories. The more you can personalize or “put a face” to your social media content, the better. You may be surprised at the results!

• Leverage Social Goodwill

Don’t underestimate the power of positive reviews. Share testimonials, case studies or photos of happy customers out and about wearing your custom apparel. Don’t be shy about asking your more regular customers for their feedback.

• Host Workshops or Giveaways

Teach the basics of T-shirt screen printing, or run a social contest with custom merch as the prize. Remote or “live” decorating events at bars, parties or local craft fairs can be another great way of generating name recognition—and bringing in additional revenue while you’re at it.

• Paid Advertising

Platforms like Facebook, Instagram and Google Ads offer powerful tools for targeting local businesses, schools or sports teams searching for customized apparel solutions. And don’t forget Impressions magazine!

Network with Fellow Apparel Decorators

Another great way to evolve is by learning from others in the industry. Networking and attending formal classes will not only help you stay up to date on trends, but spark collaboration opportunities and creative inspiration. Ways to network include:

• Attending Trade Shows—including (of course) Impressions Expo

Industry trade shows offer a wealth of networking and professional development opportunities, like this screen-printing class at Impressions Expo. Photo courtesy of Impressions Expo

Events like the Impressions Expo bring together thousands of professionals in custom apparel decoration. You can gain insights into new trends and tools while connecting with suppliers or fellow decorators or participating in the event’s professionally led educational conference sessions.

• Participating in Professional Forums and Communities

Join Facebook groups or Reddit threads for screen printing and embroidery professionals. Sharing challenges and solutions with peers can sharpen your skills and broaden your perspective.

• Attending Virtual Webinars and Industry Panels

Many brands and industry organizations host online events where experts share insider tips on marketing, production techniques, and business expansion. Examples include organizations like Fabric, the National Network of Embroidery Professionals and Shirt Lab.

• Working with a Professional Coach/Trainer

Newcomers to the decorated apparel industry are lucky in that there are a wealth of highly qualified consultants and coaches out there ready and willing to help you take your company to the next level. Invariably these will be decorators too (as opposed to the detached, somewhat bloodless consultants found more generally in the business world). More often than not, develop a relationship with a top-quality consultant and next thing you know you’ll have found yourself both a peer and a new friend.

Maximize ROI on Existing Decorating Equipment

Not every solution involves shiny new tools. You can also drive growth by optimizing how you use your current equipment. Look for ways to increase profit margins or extend the versatility of your machines.

Tips for Maximizing ROI:

• Measure, Measure and then Measure some More!

If you haven’t already then your company is already long overdue for an in-depth analysis of everything from the number of garments a particular machine can produce per hour to you cost of goods of sold, overhead costs, wastage, you name it. Simply “running the numbers” or taking a fresh look at whatever numbers you already have can be a great way of taking you company’s production processes to the next level. In the words of famed business management pioneer Peter Drucker: “You can’t manage what you don’t measure.”

• Offer Seasonal Promotions

Use existing designs and equipment to create limited-edition seasonal products. Offer discounts on holiday-themed sweatshirts or custom-printed summer tank tops.

• Streamline Workflow, Eliminate Pain Points

Evaluate your production line for inefficiencies. Automating small tasks, like garment sorting or pre-treating shirts for DTG printing, can save hours. Simply talking to your production team and finding out where their pain points are can be another way of making big wins in terms of efficiency and productivity. Create a collaborative environment in which your production people feel valued and heard. Same goes for sales, shipping and receiving, you name it. People by their very nature don’t like wasting time. They want to be productive too!

Take the Next Step Toward Growing your Apparel Business

Getting your custom apparel business out of a rut doesn’t happen overnight, but with the right strategies, growth is inevitable. Whether you’re investing in better equipment, refining your marketing strategy, or expanding your offerings, every small change can lead to a big impact.

If you’re interested in more insights and tools that can help your decorated apparel business thrive, keep exploring strategies with our expert blog series. You’ve got the creative skills, now it’s time to reignite your business by putting them to work!

The post Getting Your Apparel Decoration Business out of a Rut appeared first on Impressions.

Fabric, a vetted membership community for print shop owners, is now accepting applications for its second cohort of members, launching in July.

Founded by Bruce Ackerman (Printavo), Steven Farag (Campus Ink) and Kevin Baumgart (Sales Ink), Fabric was created to fill a gap in the decorated apparel industry by providing support, coaching and guidance to help businesses grow and thrive.

In March, Fabric launched its first set of core groups for shop owners. The three groups, each consisting of seven to 10 members working in non-competing markets, meet monthly with an executive coach/facilitator. During the meetings, facilitators help drive accountability, support goal setting and foster positive conversations in general.

Grow Your Screen-printing Shop

Per the organization, “Growing a profitable print shop is challenging. The journey involves tough decisions and often leaves owners feeling isolated and drained. Participating in a core group of industry peers creates accountability and helps owners gain clarity, support and direction.”

“We are creating a space where the business owner can become financially secure and be in full control of their time,” says Printavo’s Ackerman. “This doesn’t happen in many shops today.”

Campus Ink’s Farag adds, “I’m confident that if the shops take their core group seriously, they will move into a realm of peak business ownership.”

For more information, visit Fabric.ink.

The post Fabric Expanding Vetted Print Shop Owners Groups appeared first on Impressions.

Glimpact, a platform designed to analyze the overall systemic environmental impact of products and organizations, has launched something it calls its Global Impact Score, a publicly accessible online tool to measure and analyze the explanatory factors of environmental footprint for all fashion products in North America. Beyond measurement, the tool also helps identify the right levers for significantly reducing impact though eco-design approaches based on dynamic simulation.

Global Impact score is free to use for anyone and performs calculations according to the Product Environmental Footprint (PEF) methodological framework—an approach that looks at 16 environmental indicators across a product’s entire life cycle with the results aggregated into a single score to be understood as a sort of environmental “price.”

Water, Land Use, Eco-toxicity All Factored In

According to Glimpact, “By considering crucial categories including water use, land use, eco-toxicity and more, this systemic vision acknowledges that the environmental crisis is about more than only carbon emissions.

The company goes on to say its method has also been adopted as the scientific framework of the European Union (EU) as part of its landmark regulation ESPR, which went into force in July 2024 and is “poised to revolutionize product design practices by placing environmental performance at the heart of product development and innovation in the fashion industry.”

Apparel Industry Under Pressure to Reduce Environmental Impact

The release of Global Impact Score comes as fashion brands face rising scrutiny over their sustainability claims and prepare for stricter regulatory requirements both in Europe and globally. By providing easy access to high-fidelity environmental data, Glimpact’s tool helps shift the focus from superficial ESG gestures, such as recyclable packaging, to the high-impact upstream processes that can truly offer impact reduction leverage.

“The environmental crisis is not just about climate, it’s systemic and must take into account all components of the ecological crisis” said Christophe Girardier, founder and CEO of Glimpact. “Our new Global Impact Score tool makes the scientific methodological framework adopted by the European Union accessible to all fashion stakeholders. This empowers brands to prepare for and comply with the requirements of the ESPR, which will make it mandatory to declare the environmental performance of each product and comply with eco-design requirements.”

For more information, go to glimpact.com.

The post Glimpact Launches Global Apparel Impact Score appeared first on Impressions.

In addition to being serious about things like science, engineering and math, the students and staff at Hope Academy know how to have fun as well! Photo courtesy of L2 Brands

Hope Academy, located in Santa Lucía Milpas Altas, Guatemala, is an all-girls bilingual science, technology, engineering, arts and mathematics (STEAM) institution. The school is dedicated to empowering children from underserved communities by equipping them with the skills and resources needed for a brighter future. In addition to English and Spanish, the curriculum includes Kaqchikel, the local indigenous Mayan language, to help preserve cultural heritage. Students also gain hands-on experience through internships with local businesses.

Lisa Norris, chief merchandising officer at L2 Brands, and a couple of Hope Academy students. Photo courtesy of L2 Brands

Legacy is featured on the Hope Academy store where a curated collection of branded headwear is available for purchase. The full range includes best-selling styles, such as dad hats, structured and unstructured truckers, performance caps and knit beanies. One hundred percent of the proceeds from sales go directly to Hope Academy.

“At Legacy, we believe in the power of community and the transformative impact of education,” said Lisa Norris, chief merchandising officer at L2 Brands, parent company of Legacy and a Tree 4 Hope board member—the nonprofit that founded Hope Academy. “We’re honored to see our headwear help support the growth and education of the next generation, both in the U.S. and in our broader global community.”

“Through our unique global classroom environment, we are pioneering global education where students around the world can learn together and build communities that transcend borders while preparing them to be changemakers of the future,” said David Hope-Tringali, Director Tree 4 Hope.

Since the 1990s, Legacy and its sister company, League, both rooted in Pennsylvania, have produced premium, vintage-inspired apparel, headwear and décor. Merging in 2018 to form L2 Brands, they combine on-trend design, custom graphics, and exceptional service across collegiate, resort, corporate, and golf markets. For more on L2 Brands, go l2brands.com. For more on Hope Academy or to purchase Hope Academy merch go to wearehopeacademy.org or hopeacademymerch.org.

The post Legacy Partnering with Hope Academy to Support Children’s Education appeared first on Impressions.

According to GroupeSTAHL, the acquisition marks a bold step forward in terms of the company’s long-term vision of growing with intention, investing in innovation and expanding its customer-first model at a time when others in the industry are pulling back.” By adding TKO to such brands as STAHLS’ Transfer Express, Hotronix and STAHLS’ Fulfill Engine, GroupeSTAHL significantly strengthens its operational reach, product diversity, and production agility across North America, the company said.

GroupeSTAHL/TKO Sales Described as ‘Perfect Fit’

“TKO is a perfect fit,” GroupeSTAHL CEO Carleen Gray said. “Their strategic geographic locations, unique heat transfer technologies, and entrepreneurial culture complement and amplify everything we stand for. We’re not just adding capacity—we’re adding capability, chemistry expertise, innovation, and above all, a shared passion for helping customers succeed.”

Founded by Christian Zarate, TKO Sales quickly built a reputation for agility, quality and customer devotion, hallmarks that GroupeSTAHL’s says mirrors its own approach to business. Zarate will remain on board as president of TKO Sales, continuing to lead the company with the same energy and integrity that made it a standout player in the market.

Increased Heat Transfer Production Capabilities

“I started TKO in the middle of COVID with a dream, a plan and a lot of faith,” said Zarate. “My goal was to build a company that puts the customer first and delivers superior heat transfer solutions, day in and day out. Joining the GroupeSTAHL family is like coming home. I’ve always admired Ted Stahl and what he’s built—being part of this next chapter is a true honor.”

With over 100,000 sq. ft. of manufacturing capacity between its East and West Coast locations, TKO brings not only scale, but new formats, formulas, and talent into the GroupeSTAHL ecosystem.

“This isn’t just an acquisition—it’s an evolution,” Gray said. “Together with Christian and his team, we’re doubling down on our commitment to bring best-in-class solutions to the heat printing community—faster, smarter, and more flexibly than ever before. We’re not here to follow the market. We’re here to lead it.”

For more on GroupeSTAHL and its complete line of products and services, click here.

The post GroupeSTAHL Announces Acquisition of TKO Sales appeared first on Impressions.

Alas, for those hoping for “less interesting times” following the turmoil of the past few years, the world, for better or worse, remains as “interesting” as ever. That said, the good news as far as the custom decorated-apparel business goes is that there’s just no keeping down the decorators of the world—as was evident at this year’s first two Impressions Expos (impressionsexpo.com).

The 2025 Long Beach expo was one for the record books, with over 300 exhibitors reserving 124,000-square-feet of floor space. Photo courtesy of Impressions Expo

The first expo of the year, in Long Beach, California, was literally one for the record books, with over 300 companies reserving an incredible 124,000-square-feet of floor space, making it the biggest Impressions Expo ever. The show was literally sold out. The energy was also one for the record books, with packed rooms at the show’s educational conference series, and hundreds more checking out the Ink Kitchen’s Shop Talk stage out on the show’s main floor.

As for the year’s second Impressions Expo in Atlantic City, New Jersey, while not as big as the Long Beach event, it was no less promising, with respect to the industry’s future especially. Indeed, afterward many exhibitors were heard to say it was just as good or even better in terms of the number of leads generated and sales made as Impressions’ premier Long Beach event—high praise, indeed!

As for the products and services on display, which included more than a few industry debuts, suffice it to say, the industry as whole is continuing to steam full speed ahead. Blank apparel, sustainability, the latest decorating tech, you name it: recent trends not only remain very much in play, but continue to build momentum. The end result is an industry with as bright a future as ever, come what may.

Direct-to-film (DTF), Digital Decorating

Not surprisingly, digital decorating was once again the big story, especially in the area of direct-to-film, or DTF. Indeed, so ubiquitous has DTF become, it’s hard to believe the technology was still considered “cutting edge” only a few short years ago.

Yet another sign of the times: M&R’s second new DTF printer in as many years. Photo courtesy of Impressions Expo

Everywhere you looked at both expos (and at the 2024 Impressions Expo in Texas last October, as well) you couldn’t help but see further evidence of this fact. Printers, heat presses, DTF transfers and custom transfer services, you name it—DTF was and looks to continue to be evident everywhere.

In terms of printer tech, among the standouts were the new Epson SureColor G6070 DTF printer, the company’s first all-DTF system, following in the footsteps of the company’s SureColor F1070 hybrid DTG (direct-to-garment)/DTF system. Long a provider of the basic nozzle technology found in countless machines across the printing world, the new SureColor G6070 is especially notable for its ease of maintenance, a key factor when DTF printing at scale.

Another notable debut was M&R’s new Quatro 68 DTF printer, a larger version of the same type of Quatro printer introduced in 2024. Clearly, the company’s foray into commercial-scale DTF printing is more than just a whim. On the contrary, the renowned screen-printing equipment supplier clearly means business. Further evidence of this fact could be found in the company’s Quatro Cutter X DTF transfer film cutter, designed to automatically cut the continuous line of transfers coming off a DTF printer into workable sheets—a big time saver no matter what size shop you’re running.

ROQ’s new IMPRESS automated heat-press system. Photo courtesy of Impressions Expo

Then, of course, there’s the new fully automated ROQ IMPRESS “system,” composed of what is in essence a heat-press version of the screen-printing autos the company has long produced and a trio of complementary systems: the FEED, PEEL and PULL, which pretty much do what their names say, i.e., automatically place each transfer; remove the backing material when heat-pressing is complete; and then remove the fully decorated shirt, leaving little more for an operator to do other than thread each garment onto a platen.

Meanwhile, the battle royale that is the current state of the custom transfer industry continues, unabated, as the major players in this area all continue slugging it out in the form of a seemingly never-ending stream of new products and services—including both a wide range of transfer types and an equally wide range of shipping options, making their products cheaper and easier to work with than ever.

613 Originals, for example, was touting such new products as its new DTF Hybrid Heat Transfer and its White Puff and Full Color glow in the dark lines.

Similarly, Ninja Transfers, after bursting onto the scene only a couple of years ago, continues to push the envelope. New initiatives on offer included everything from the company’s “AI Upload” design tool to the expansion of its film offerings with an array of new styles, including glitter, glow-in-the-dark and the company’s newly added gold and silver foil films line.

In the wake of Impressions Expo Atlantic City, Ninja Transfers also recently announced the launch of a new business it’s calling Ninja Blanks, a curated line of premium blank apparel—the company’s latest initiative designed to make getting involved in heat pressing as easy as possible.

Finally, there was industry stalwart STAHLS’ and it’s Hotronix heat press and Transfer Express custom transfers lines. As is the case with its competitors, STAHLS’ had a number of new products on offer, including its EasyRip option, which allows decorators to separate a set of ganged transfers by hand. Making an equally big splash was STAHLS’ new Fulfill Engine, an “all-in-one” online business management software system encompassing everything from e-commerce and online company stores to the nuts and bolts of shipping and receiving—not just for heat press decorators but decorators of all kinds, including embroiderers and screen printers.

Machine Embroidery in the Computer Age

Speaking of the embroidery business, equipment and materials suppliers continue to push the envelope in this area as well, with a focus on both ease-of-use and sustainability.

Embroidery systems specialist Melco is making waves with its Fusion e-commerce and embroidery software system, and the Summit 16-needle embroidery machine. Photo courtesy of Impressions Expo

Case in point, Melco debuted not one but two new products, the Melco Fusion e-commerce and embroidery software system, and the Melco Summit 16-needle embroidery machine. The former is described as “a cloud-based web service hosted by Melco that generates product previews and embroidery-ready files using data submitted by users on your e-commerce website.” The latter, among other advances, includes a laser alignment and positioning system, and a built-in barcode reader to ensure the right garment gets the correct design in every case.

Not to be outdone, Germany’s ZSK was also touting a pair of cutting-edge systems—it’s super-fast Racer-R embroidery machine and the newly revamped EPS Hoop Station. Alas, the Racer-R system got held up in transit and couldn’t make it to the Long Beach show in time. Suffice it to say, though, the new system promises to be a powerful piece of equipment and then some, offering stitching speeds of over 2,000 stitches per minute. Available in both single- and multi-head configurations, the Racer-R is also designed to reduce vibrations and noise levels with an eye toward creating a safer and more comfortable work environment. A modular embroidery head facilitates quick replacements as well, ensuring minimal down times.

As for the EPS Hoop Station, this nifty piece of equipment allows operators to visualize how best to position a garment prior to stitch-out by projecting an image of the design to be embroidered onto an accompanying hooping jig, thereby minimizing placement errors. Think the same basic concept as STAHLS’ award-winning ProPlace IQ system, which essentially does the same thing when heat pressing.

Finally, there was Ricoma’s new 20-needle embroidery machine line, featuring a 10.1-inch touchscreen user interface, and Madeira USA’s new Polyneon Green Thread. The latter, coming fast on the heels of the company’s sustainable E-ZEE Cut Green backing product, is made entirely out of 100-percent recycled post-consumer PET bottles while still providing the same strength, brilliant colors, shine and overall outstanding performance of the company’s other threads.

The new Ricoma machines, which are available in single-, double- and three-head configurations, feature the combination of an oversized embroidery area to accommodate larger designs and 270-degrees of rotation for “ear-to-ear” cap embroidery.

Clearly, the embroidery industry is doing everything it can to make sure DTF doesn’t get all the attention!

Blank Apparel, Direct-to-Garment (DTG) and Sustainability

Returning to digital decorating for a moment, as is the case with its move into DTF, ROQ is continuing to show its commitment to DTG with the company’s new, fully revamped NOW “100-percent digital printing machine.” Capable of processing up to 250 garments per hour, the NOW includes everything from a pre-treat component to a pressing station, flash-cure station and multiple print stations for both white ink and full-color—basically everything you need for fast, efficient high-quality decorating.

Let the new ROQ NOW digital decorating system serve notice: digital decorating is here to stay. Photo courtesy of Impressions Expo

As for screen printing, it feels a bit strange not getting to what once served as the industry’s preeminent decorating technology until the latter part of a survey article like this. However, it feels like it has been put on pause for a bit in terms of basic printing technology. Today’s autos, for example, remain paragons of precision, productivity and efficiency; same thing with today’s screen production tech—one of the reasons screen printing remains a leading decorating method despite the inroads being made by DTF and DTG.

That said, one area in which the industry continues to see gains is in screen reclamation. Of particular interest is the work being done to make the process as sustainable as possible, with an eye toward keeping as many toxic chemicals as possible out of the waste stream.

Given today’s tight labor market, this is also an area in which equipment manufacturers are doing everything they can to make the job as pleasant as possible in an effort to help decorators retain workers. The result has been such automated systems as M&R’s ECO-TEX modular automatic screen cleaning and reclaiming system; ROQ’s newly introduced JetBlack automated screen reclamation system; and the extensive line of screen reclamation systems and chemicals being produced by such companies as Easiway Systems and Bluewater Labs.

ZSK’s newly revamped EPS Hoop Station helps ensure each and every garment is hooped as it should be. Photo courtesy of Impressions Expo

Finally, in the world of blank apparel, the industry’s leading manufacturers seem to be continuing to work along two separate but often overlapping, tracks: ease of decoration and sustainability.

With respect to the ease-of-decoration side of the equation, one of the standouts for 2025 has been Gildan’s new Plasma Printing tech, which works by integrating a series of specialized softeners directly into a garment’s fabric as a part of the manufacturing process. The result is a garment that minimizes or even eliminates the need for pre-treatment when DTG apparel printing, long the bane of DTG decorators, especially those lacking the resources for systems like the ROQ NOW.

No mean feat from a production standpoint—or in terms of the exact chemistry that makes it possible—Gildan’s Plasma Printing tech is the kind of breakthrough that may prove to be a real game-changer. It will be interesting to see the impact of this latest move by Gildan’s, both on its competition and the decorated-apparel industry as a whole.

As for the sustainability side of the equation, it’s great to see the blank apparel industry’s efforts to minimize the environmental impact of its products not just continuing but becoming even more entrenched. Whether you’re talking headwear, fleecewear or the latest crop of tees, green materials and manufacturing processes remain the name of the game.

Among the standouts would be Italy’s Atlantis Headwear with caps like the Fiji, a structured five-panel baseball cap made of 100-percent recycled polyester complete with a “Retraze” bill made of recycled plastic waste removed from the world’s oceans; Lane Seven’s continued commitment to sustainability with its “Future Fleece” line, made of 100-percent recycled yarn; Otto Cap’s new “5 Panel Pro Style Baseball Cap” made of recycled Taslan Nylon; S&S Activewear’s new Pro-Flex performance fabric composed of 60-percent polyester pin-dot mesh and 40-percent Sorona, a partially plant-based polymer; and Allmade’s newly released Unisex Organic CVC Fleece Pullover Hoodie, incorporating 60-percent organic combed ring-spun cotton and 40-percent recycled polyester.

Hanes celebrated the 50th anniversary of its Beefy-T T-shirt line at the Long Beach show with a fun heat-pressing activation. Photo courtesy of Impressions Expo

Kudos as well to Hanes, which celebrated the 50th anniversary of it Beefy-T T-shirt with a magnificent heat-pressing activation at the Long Beach show and the release of a new Beefy-T Retro Street Tee. Same thing for Live & Tell by L.A.T.’s Vintage Wash line, which employs a proprietary pigment dying process that results in fabric that is comfortable as it is easy to decorate; and Gildan’s Comfort Colors line, also marking its 50th anniversary.

Finally, a shout out to the Chinese company S.E.C. Accessories Limited and its fully automated, self-contained heat-press robot. Somewhat analogous to the mixed-drink robots that have been around a few years now, the system may not yet be ready for prime time in terms of mass production—especially in light of the many advances in automation already mentioned. Nonetheless, it would make for a heck of an on-site novelty at, say, sporting events. Then again, the way the industry is proceeding these days, who knows?

The post Special Report: Impressions Expos and What’s New for Custom Decorated Apparel in 2025 appeared first on Impressions.