The MerchMaker heat press offers a rare combination of top level features, streamlined design, and affordability, making it a smart entry point for entrepreneurs and small businesses ready to launch or expand their custom apparel operations.

Designed to help garment decorators achieve professional results with every press, the MerchMaker combines smart functionality with space-saving portability. It’s the ideal solution for startups, crafters, small shops, and on-the-go entrepreneurs who want to take on more custom orders with confidence and consistency, with features not found in other presses at this price point.

Engineered with both function and flexibility in mind, the MerchMaker allows decorators to press with precision in even the smallest of workspaces or live events, pop-ups, or market spaces.

A New Standard in Entry-Level Heat Presses

The MerchMaker stands out with features typically reserved for higher-end machines, including:

• Dual Functionality: use as a traditional clamshell or pull-out draw press
• Smart Display: LCD screen shows time, temperature, and pressure for consistent results
• Fast Heating: heats quickly to 300°F – ideal for transfers and HTV
• Perfect Pressure: patented over-the-center pressure adjustment ensures even application
• Lightweight & Portable: designed for tight workspaces and on-the-go availability
• Safety Certified: (UL/ULC/CE), with 110v standard operation

Getting Started Made Easier with Bonus Marketing Kit

To support new decorators, Transfer Express is including a free Marketing Kit (a $75 value) with every MerchMaker purchase. The kit includes heat transfers samples, educational materials, how-to guides, application charts, and more tools to help decorators promote, produce, and profit from selling custom apparel successfully.

The post Transfer Express Launches MerchMaker: The Ultimate Value Startup Heat Press appeared first on Impressions.

This strategic collaboration gives Ninja Transfers customers access to a curated selection of industry-leading heat press machines, trusted by pros and hobbyists alike, now available at NinjaTransfers.com. These presses are fully optimized for Direct-to-Film (DTF) transfers offering customers the tools they need to bring production in-house, boost profits, and scale with confidence.

“We’re always looking for ways to support our community of Ninjas,” said Victor Ilisco, Director of Business Development. “Partnering with Heat Press Nation lets us connect our customers with tools that match the quality of our transfers—making it easier for them to take ownership of their craft and grow on their own terms.”

Key Benefits of the Partnership:

● Boost Profit Margins: Bringing heat pressing in-house drastically reduces costs per garment compared to outsourcing.

● Increase Quality Control: Control every aspect of application for consistent, professional results.

● Enable Business Growth: Perfect for creators ready to scale — whether starting a side hustle or running a growing brand.

By integrating equipment and materials under one roof, Ninja Transfers continues to eliminate friction for creators—making it easier than ever to go from idea to execution.

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Taking place on Wednesday, July 17th, from 1:00 PM to 4:00 PM at Lane Seven’s Irwindale location, this half-day event will provide valuable insights, practical strategies, and expert guidance to help attendees enhance operational efficiency, expand their product offerings, and maximize profitability through heat printing.

Partnering with Lane Seven Apparel, STAHLS’ Heat Press Pro Day will offer attendees an opportunity to engage in high-impact, hands-on training led by industry experts. Participants will gain real-world strategies to improve operational efficiency, harness the power of e-commerce, and diversify their product offerings with heat printing. In addition, attendees will learn critical pricing calculations and business strategies to ensure they are maximizing their bottom line.

“We are excited to provide an opportunity for attendees to not only learn from the experts but to experience firsthand how heat printing can transform their business,” said Kelly Walters, STAHLS’ Director of Experiential Marketing. “This hands-on event is designed to help decorators enhance production and find new ways to grow in a competitive market, with live demos and real techniques they can instantly incorporate in their operations.”

The Heat Press Pro Day Experience:

• Hands-On Training with Industry Experts: Engage in interactive sessions covering the entire decoration process, from setup to application.
• Comprehensive Business Growth Strategies: Gain insights to increase production efficiency and enhance profitability, with new ways to stay ahead in a competitive industry.
• Exclusive Merch & Promos: Receive a curated set of branded merchandise and exclusive product credits to showcase what’s possible with STAHLS’ products.
• Networking Opportunities: Connect with fellow decorators and entrepreneurs, share experiences, and foster a supportive community.

Bonus: Each attendee will receive a $50 product credit to be added to their STAHLS’ account after the event.

With attendance limited to 100 participants, Heat Press Pro Day promises an intimate, impactful experience that allows for personalized interaction with experts. Interested decorators should register as soon as possible to secure their spot. For more details and to register, visit transferexpress.com/heat-press- accessories/heat-press-pro-day.

The post STAHLS’ & Lane Seven Team Up to Empower Apparel Decorators appeared first on Impressions.

Philadelphia, Pennsylvania-based Ninja Transfers, a leader in custom direct-to-transfer (DTF) manufacturing is once again “raising the bar” with the introduction of spangles as part of its ever-expanding lineup of decorating options.

Spangles, an eye-catching embellishment style that employs a series of reflective flat discs heat-applied to the apparel being decorated, are fast becoming a favorite among apparel decorators. Unlike rhinestones, spangles have no sharp edges and are lighter, smoother and more durable, making them perfect for everything from youth apparel and cheer uniforms to fashion-forward streetwear.

Easy-to-apply Bling for Heat Pressing

According to Ninja Transfers, “What makes spangles so exciting for creators is the technology behind [them.] The machines used for applying spangles are highly modified embroidery platforms that precisely place individual sequins in custom designs with speed and consistency. The result? A high-end look with mass production efficiency, without the hassle or limitations of traditional bling.”

Ninja Transfers is offering spangles as a new, premium decoration method that allows customers to create eye-catching designs with incredible dimension and light reflection. Designers, influencers and small custom apparel decorating businesses alike now have access to this cost-effective means of elevating their brand presence.

Cutting Edge Apparel Decoration

“Spangles are bold, fun, and undeniably eye-catching—exactly the kind of customization our customers are asking for,” said Victor Ilisco. “We’re thrilled to make this innovation more accessible and offer something that sets our community apart.”

For more on Ninja Transfers’ new spangles option as well as 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.

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All Hotronix models are in stock and ready to ship, ensuring decorators can maintain production schedules without the uncertainty tied to overseas equipment sourcing.

“When decorators invest in Hotronix, they’re getting U.S.-engineered quality, next-day shipping, and the confidence of long-term reliability,” the company stated. “It’s smart business protection in today’s unpredictable market.”

Key Benefits of Hotronix Heat Presses:

Tariff-Free Assurance: Domestic production means no surprise cost increases from international trade shifts.

Reliable Availability: All models ship quickly from U.S. warehouses, with consistent stock and short lead times.

Built in the USA: Each unit is engineered to meet rigorous performance standards for durability and consistent results.

Lifetime Warranty: Every Hotronix press includes a lifetime warranty on the heating element, offering peace of mind and long-term value.

With continued volatility in global supply chains, Hotronix heat presses present a stable, high-performance solution for businesses of all sizes looking to secure their equipment investments and avoid costly delays.

The post Hotronix Offers Tariff-Proof, American-Made Heat Press Solutions appeared first on Impressions.

There’s something special about pulling on a jersey with your name and number for the first time. Whether it’s a young athlete getting their first team uniform, a company softball team suiting up for some friendly competition or a pro athlete stepping onto the field, those numbers and letters create a sense of identity and belonging.

Heat printing has revolutionized the way teams big and small get personalized uniforms quickly and affordably. From classic block numbers to modern metallic, reflective or multi-color designs, today’s technology makes anything possible. The same techniques that bring instant customization to stadiums and high-profile events, like the NFL Draft, are also helping local sporting goods stores and print shops fulfill orders with ease.

So, how do the pros do it? What are the best methods and materials for different fabrics and team styles? Whether you’re gearing up for a championship season or outfitting a weekend league, here’s a behind-the-scenes look at the latest trends and tools in team jersey printing.

Heat Transfers: A Winning Strategy for Team Jerseys

Screen printing has long been the go-to method for decorating team jerseys, especially for bulk orders where the same logo is printed over and over. It’s efficient, cost-effective and delivers durable results that stand up to the wear and tear of a season. However, when it comes to individual personalization—adding player names and numbers—heat transfers are the industry standard. Whether it’s a little league team, a local rec squad or a pro-level event, heat printing offers the flexibility to customize each jersey on demand.

In fact, when it comes to this kind of customization, one of the biggest challenges in uniform printing isn’t the application—it’s the design process. Creating artwork, inputting player names and numbers and ensuring accuracy can be tedious and time-consuming. You may therefore want to consider using an online designer, such as the STAHLS’ Team Builder platform (part of the STAHLS’ family of companies, including STAHLS’ Transfer Express) to streamline the process.

The key to an online design platform, like STAHLS’ Team Builder, is the fact it allows you to upload a team roster and instantly generate ready-to-print designs for each jersey. This is true whether you’re ordering DTF transfers or screen-printed transfers. No more typing in names one at a time or having to worry about misprints; an online design platform Team Builder automates the process, ensuring consistency and efficiency.

With the right software, you can personalize jerseys in just a few clicks. The software allows you to input a roster and apply personalized text across all jerseys instantly. Additionally, you can see live mockups and pricing, which means you get to see your designs in real time and obtain accurate quotes before ordering.

If you have custom logos, you can also upload them and incorporate any team branding you’d like for a polished, professional look.

So far, so good. Bear in mind, though, that in addition to having to decide whether to go with an online designer and service provider or not, you also need to select a decorating method. Among the more well-established options out there are direct-to-film (DTF), screen-printing and hybrid transfers, with pricing varying by transfer. Beyond that, another couple of options to consider include pre-cut and pre-spaced numbers.

Pre-spaced numbers and names make the heat-pressing process that much easier and faster. Photo courtesy of STAHLS’

Traditionally, pre-cut numbers and letters, also known as die-cut numbers, have allowed for effective on-demand personalization. Granted, having to manually align each individual character can be time-consuming. Nonetheless, pre-cut numbers, such as STAHLS’ Thermo-FILM numbers, have long been the fastest, easiest and most cost-effective way to add numbers to jerseys. Specifically, with a heat press, it’s possible to print as many as 15 numbered team uniforms in 30 minutes or less. Pre-cuts are available in multiple styles, sizes and colors, including two-color options, offering a word of possibilities.

Making things even easier are Pre-Spaced Numbers and Pre-Spaced Text, which arrive on a single carrier sheet, eliminating alignment issues and reducing application time. While slightly more expensive, they save labor costs in the long run. If you want to save even more money and bring it all in house, you can always cut your names and numbers yourself using a vinyl cutter and any number of different CAD-CUT materials as well.

Heat transfer vinyl (HTV) is another popular method for customizing small batches of uniforms, especially when dealing with one-off orders or teams with frequently changing rosters. It is especially effective for stretchable, moisture-wicking sportswear, as newer vinyl formulations provide flexibility and durability.

It’s for this reason that many professional and college teams, not to mention large leagues, will have a cutter and a heat press in their locker rooms to make sure they always have the right jersey for a player who needs to take the field. Note: decorators typically apply heat-pressed numbers separately when using sublimation for team jerseys.

Emerging Trends in Team Uniform Printing

As team sports gear evolves, decorators must stay ahead of emerging trends. Here are some of the top innovations shaping uniform customization in 2025:

1) Performance-Driven Materials

Athletes expect uniforms that enhance performance through lightweight, breathable, moisture-wicking fabrics. However, traditional printing methods, like screen printing, can sometimes interfere with breathability. Recommended printing solutions include:

• Stretchable heat transfer vinyl for maximum flexibility
• DTF transfers that bond well with polyester without restricting movement
• Silicone heat transfers to prevent dye migration on synthetic fabrics

2) Hybrid Decoration Techniques

Many decorators are now layering multiple heat-applied techniques to create more dynamic and premium designs. Popular hybrid approaches include:

• Dimensional transfers: Raised silicone or soft foam transfers add a tactile effect.
• Overlaying transfers: Combining full-color transfers with heat transfer vinyl for depth and texture.
• Patches & emblems: Adding embroidered or silicone patches for a high-end look

3) On-Demand Customization & Digital Ordering

Speed is key in today’s market. Many decorators are using online design tools to streamline the uniform ordering process. Some design platforms allow customers to enter team rosters, select fonts and colors, and preview designs before placing orders. Essential tools for on-demand printing include:

• Online team building design software to help generate mockups
• Pre-stocked blank uniforms to ensure rapid turnarounds
• Auto-open heat presses to facilitate faster production times

Winning Business in Team Sports Printing

Expanding into the team uniform market requires a strategic approach. With this in mind, here are some steps to help you establish a successful operation:

1. Invest in the right equipment: Whether you’re using a screen-printing press, a heat press, or a DTF printer, having the right equipment ensures efficiency and quality.
2. Offer personalization services: Providing heat-applied names and numbers is essential for attracting team orders.
3. Stay up to date with trends: As sportswear fabrics evolve, choose decoration techniques that maintain breathability, stretch and durability.
4. Simplify ordering for customers: Offering an online design and ordering tool can make the process seamless for coaches, league organizers and team managers.
5. Optimize your workflow: Using pre-spaced numbers and letters, along with an efficient heat press setup, can significantly cut down production time.

The Right Decoration Method for Every Job

The team uniform market offers a wealth of opportunities for decorators, but success depends on selecting the right printing method. Remember, you will probably have to use a combination of different methods depending on the sport, the type of jersey and the desired finished look.

By combining heat-printing methods strategically, decorators can create professional, durable and visually appealing team uniforms while maximizing efficiency.

Karin Bellinghausen is vice-president of communications for GroupeSTAHL, parent company for acclaimed heat-press manufacturer STAHLS’ Hotronix and custom DTF and heat-transfer materials supplier STAHLS’ Transfer Express. In addition to its online design software, the company also result debuted the comprehensive e-commerce and online business service, STAHLS’ Fulfill Engine.

The post Winning Techniques for Decorating and Numbering Team Sports Uniforms appeared first on Impressions.

Impressions Magazine: What do you see as the overall outlook for DTF decorating in the coming years? Do you expect to see continued growth? If so, why?

Ninja Mike: One hundred percent! DTF and UV-DTF transfers have exploded in popularity over the last few years, and they’re only gaining steam. What used to be, “Can I even do this?” is now, “How fast can I get it done?” It’s changed the game for decorators, brands and entrepreneurs alike.

DTF gives you superpowers. You can print on nearly any product, material or color with any design without any headaches. Ten designs on 10 different garment types and colors in various locations? No problem. You’re not wasting time figuring out what’s possible anymore—you’re just saying, yes, and that means faster growth, happier customers and more profit. No longer do you need to run the job and costing by an expert. Anyone can do it, because the answer is basically always, yes. It’s a complete mindset shift for the industry.

Advantages to DTF Custom Decorating

IM: Can you provide us with an overview of some of the advantages of DTF decorating over, say, screen printing? How would you compare the costs of screen-printing apparel to DTF?

NM: What’s exciting is that DTF has come so far most customers can’t tell it apart from screen printing—and often it feels even better, especially on performance fabrics, like nylon or polyester.

Screen printing still makes sense for high-volume shops that are optimized for it, but DTF steps in wherever screen printing slows you down. It also requires a far smaller footprint. No giant auto press. No screen reclaiming. Just a heat press, a table, and you’re in business.

The no-minimums part of the equation is also huge. With DTF, you can gang a ton of designs on one sheet and order exactly what you need. That means no wasted money or inventory. Also—and this is big—full color doesn’t cost more. Whether it’s a five-color logo, single color or a photorealistic design, you’re only paying for space, not complexity.

Decorating hard-to-print items like hats, bags or jackets? DTF crushes screen printing. Why spend time with your most talented printer trying to accomplish a single-color screen print on a tricky item when a brand-new employee trained for 30 minutes in DTF can press a full-color DTF transfer for you flawlessly? The answer is: you shouldn’t. If you are still doing it the hard way, I challenge you to give DTF a try on your hardest-to-print product. You’ll be a believer, instantly. I’ll even guarantee it or your money back on your DTF transfers for that order.

Today’s DTF transfers are good enough they can work just as well or even better than screen printing. Photo courtesy of Ninja Transfers

Sleeve and leg prints are also so easy with DTF. Screen printing on them can be a pain. I know this for a fact having run a screen-printing shop for over 20 years. But with DTF, even multi-color sleeve prints are simple. The more complex the print, the better, because DTF can handle the color and detail with ease without any registration issues.

In terms of cost, if you factor in all the costs, time, risk and space required to run a screen-printing shop—including training printers, prepping orders, ensuring everything is perfect in advance of each print run, then breaking down the screens, and cleaning and reclaiming them—then compare it to DTF, you’d be amazed at the accessibility and ease the latter provides. It is hard to quantify the exact cost difference, but with DTF your costs are well known ahead of time, because you know your cost per transfer. By contrast, with screen printing, your costs can vary greatly as a result of printing problems, having your printers not show up, running low on ink, you name it. Machines can also go down and your shipping costs increase due to production runs taking longer than expected and having to expedite deliveries. This simply won’t happen when DTF decorating, because your timing and the outcomes are so predictable.

When you really break it down—including all the labor, training, screens, risk, rescreens and setup costs that come with screen printing—DTF just makes more sense. It’s faster, easy to learn, more consistent and incredibly scalable. You can quadruple production capacity within the confines of the same space simply by adding more heat presses and tables. It’s that flexible.

Get good at DTF, and your costs will drop fast. Once your team and processes become efficient and you are as confident as we are with DTF, you’ll scale up, and your cost per press will plummet at the same time margins skyrocket.

DTF Custom Apparel and Larger Production Runs

IM: Some say DTF struggles with large production runs. What’s your experience been?

NM: That used to be true, but not anymore. With today’s hot-peel transfers, you don’t have to wait for them to cool—you just press and peel, instantly. A simple heat press gets the job done. As you scale up you can also start investing in dual-platen heat presses, which make it possible to load the next item while the current one is still being pressed. Add a few extra heat presses, and you’ll be cranking out high-volume jobs in no time.

When we started, we saw a lot of one- to 100-piece orders. Now, 500-plus-piece runs are normal. Again, once you dial in your workflow, DTF scales beautifully, way more easily than having to manage an additional screen-printing setup with inks, screens, dryers, reclaim, power washers and so on. Ten heat presses can handle what used to take an entire print shop.

IM: On the custom DTF supplier side of the equation, the industry continues to make great strides in the areas of “feel” and special effects. Can you comment on some of the recent advances being made by both your own company and the industry as a whole?

NM: DTF has gotten way softer, stretchier and more durable. At Ninja Transfers, we’ve tested over 100 combinations of film, ink and TPU powder to get our transfers just right. The result is transfers with a soft matte finish, 60-wash durability when machine drying and over 100 washes line-dried.

The entire industry, Ninja Transfer included, has also begun rolling out a wide range of specialty films, including glitter, glow-in-the-dark, metallic gold and metallic silver. We’ve also added puff transfers to our lineup. These days DTF doesn’t just compete with screen printing, it opens up all kinds of new creative options.

That said it’s important to be aware that not all transfers are created equal. Same goes for custom DTF transfer providers. There are a number of quality custom transfer providers here in the United States—including, of course, Ninja Transfers. However, there are also plenty of no-name outfits out there, whose quality is shoddy to say the least. Bottom line, you get what you pay for. That goes for customer support, quick turnaround times and expedited shipping as well.

Here at Ninja Transfers, we’ve invested over $3 million in building a state-of-the-art facility with precise climate control, top-tier consumables, proprietary software, AI tools and constant testing. Why? Because quality needs consistency. We also test our transfers over 20,000 times a day on real garments across all order types. That kind of real-time feedback gives us a huge edge catching issues before they reach our customers, which in turn ensures your transfers will not have pressing problems. In the event a customer does ever encounter problems or have any questions, we provide 24/7/365 customer service.

In terms of judging the quality of a DTF transfer, the first question you need to ask yourself is, “After it’s washed, does it still look great?” It should. Beyond that, do the transfers peel easily and cleanly every time? You shouldn’t be holding your breath or pulling it at the speed of sound in order to get the design to successfully separate from the transfer. The process should be smooth, satisfying and predictable—hot or cold, fast or slow.

On side note, as with any business, a DTF company’s values and overall business philosophy can also tell you a lot about the products and services it provides, and at Ninja Transfers we always strive to do and be the best we can. As of this summer, for example, our production facility will be 100-percent powered by solar energy. Ninja Transfers’ consumables are also all OEKO Tex Certified, a globally recognized safety standard; the company donates hundreds of thousands of dollars to over 35 not-for-profits, including youth educational programs, the ASPCA and St. Jude Hospital. Ninja Transfers also makes a donation with every order to facilitate carbon-neutral shipping.

IM: Any final thoughts for shops still on the fence about DTF?

NM: If you haven’t tried DTF, now’s the time. I can’t stress enough what a difference it can make. It’s the one solution that works on nearly everything. Once you start, you’ll wish you had sooner. 

For more on Ninja Transfers and its complete line of products and services, including DTF transfers, patches, blank apparel and its Ninja Printhouse blind-shipping subsidiary, go to ninjatransfers.com. To see Impressions’ earlier conversation with Ninja Transfers’ “Ninja Mike,” click here.

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Philadelphia, Pennsylvania-based Ninja Transfers, a leading provider of direct-to-film (DTF) transfers for the custom apparel and merch sectors, has announced it will not increase prices on any DTF transfers through the end of 2025. Even as global tariffs continue to affect supply chains, the company says it is choosing to absorb rising costs in order to support its customers and help businesses of all sizes stay competitive.

“Our mission has always been to empower creators, entrepreneurs and businesses by providing top-quality DTF transfers at accessible prices,” said Victor Ilisco, director of business development at Ninja Transfers. “Even as external economic pressures mount, we believe in absorbing these challenges to ensure our customers can continue to thrive without the added burden of increased costs.”​

Price Freeze/Programs Designed to Help Offset Tariff-associated Expenses

In addition to freezing prices, Ninja Transfers has also introduced a number of initiatives intended to further enhance customer value. Among these is a program the company calls its “Cumulative Discounted Pricing model,” which rewards customers with increasing discounts based on their total purchasing volume, making it more affordable for businesses, side hustlers and merch and custom decorated apparel hobbyists to access top-quality DTF transfers at the best price. ​

The company has also introduced something it calls its “Ninja Rewards Program,” a loyalty and rewards program that recognizes and rewards customers with real dollars off their future orders. ​

According to the company, “These initiatives reflect Ninja Transfers’ holistic approach to customer satisfaction, combining affordability with innovation and sustainability.​”

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.

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With more than 25 years of experience in textile printing, garment decoration and international sales, Heuer joins STAHLS’ at a key time in its history as the company continues to focus its efforts on growth outside the United States.

In his new role, Heuer will lead sales efforts across the EMEA region and work closely with Martin Borley, executive managing director for STAHLS’ UK & Europe, and Stephanie Schnur, managing director of STAHLS’ Europe.

STAHLS’ Focusing on Growth outside the United States

“We are delighted to welcome Thomas Heuer to STAHLS’ as our new director of sales for EMEA,” Borley said. “Thomas brings an impressive blend of experience, leadership and industry knowledge that will be crucial in driving our growth across the region. His strategic approach and customer-focused mindset align perfectly with our vision to expand and innovate within the garment decoration industry.”

“Thomas’s track record in building high-performing sales teams and driving innovation makes him the ideal choice to lead our sales strategy in EMEA,” said Carleen Gray, CEO of STAHLS’. “His leadership will help us bring more of our advanced decorating technologies to customers around the world.”

In his role as part of the STAHLS’ team, Heuer will support STAHLS’ sales efforts with  respect to such heat-press custom apparel decorating solutions as UltraColor Pro hybrid transfers, UltraColor MAX DTF transfers, 3D Silicone Heat Transfers and the entire line of Hotronix heat presses.

“I’m honored to join STAHLS’ during such an exciting time,” said Thomas Heuer. “STAHLS’ stands for innovation, quality, and customer-first solutions. I look forward to helping grow our impact and support decorators across the region.”

For more on STAHLs” and the company’s entire line of custom apparel-decorating products and services, click here. For more on the company’s Hotronix custom apparel heat press division, click here. For more on the company’s custom direct-to-film (DTF) and heat-press transfer division, Transfer Express, click here.

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Though it can be a problem when working with performance apparel, with the right techniques and tech, scorching can be eliminated, even on tricky fabrics. Photo courtesy of STAHLS’ Transfer Express

But don’t worry—scorching doesn’t have to be the end of the story. Heat printing is one of the most versatile and efficient decoration methods around, offering quick turnaround times, customization and the ability to decorate nearly any fabric or design location, including those other methods decorators struggle with as well. With the right knowledge and techniques, you can prevent heat-related damage and keep your garments (and reputation) intact.

This guide will break down why scorching happens and provide practical tips to help you achieve flawless, scorch-free heat printing every time.

How Heat Press Scorching Happens

To address the issue, we first need to understand what scorching is. Simply put, scorching occurs when garments—especially those made with synthetic or plastic fibers, like polyester—are exposed to excessive heat or pressure during the heat-printing process. The result can range from a visible press box or shiny fabric to discoloration or even a burnt garment.

At its core, scorching happens because the fibers in the fabric begin to melt or degrade under high heat. The reaction can differ depending on the garment material, making it essential to recognize how different fabrics respond to higher temperatures. Whether it’s polyester, nylon or the newest trending synthetic material, knowing how to prevent scorching allows businesses to protect their bottom line while minimizing waste.

For decorators, scorching isn’t just an annoyance, it can directly affect profits. Sending out garments with press boxes, burns or discoloration can lead to dissatisfied customers, tarnished trust and even lost business.

Smaller platens can be useful for isolating print areas, thereby reducing the risk of scorching the surrounding fabric. Photo courtesy of STAHLS’ Hotronix

Yet, the solution isn’t as simple as just lowering the temperature. Heat transfers require precise settings—time, temperature and pressure—to adhere properly and ensure longevity through wash and wear. Lowering the heat too much risks producing garments that appear fine initially but crack, fade or peel after repeated use, damaging your reputation as a reliable decorator.

Maintaining quality and customer satisfaction requires balancing these factors while taking steps to prevent scorching before it happens.

In addition, preventing scorching is not just about preserving the quality of individual garments, it also plays a role in reducing waste and promoting sustainability in the heat-printing industry. In a world and in an industry that have become increasingly aware of the environmental impact of fast fashion, every wasted garment contributes to the growing problem of textile waste in landfills.

By mastering techniques to avoid scorching, apparel-decorating businesses can minimize the number of misprinted or damaged items, extending the life of the apparel and reducing the need for replacements. This approach in turn aligns perfectly with broader efforts to create a more sustainable future, where quality and care go hand in hand with environmental responsibility.

Best Practices for Preventing Scorching When Apparel Decorating

Preventing scorching starts with understanding your materials and the decoration method you’re using. Certain fabrics, like polyester and tri-blends, are more prone to scorching due to the nature of the synthetic fibers they employ. Dark-colored polyester, in particular, tends to show visible press marks. When working with these materials, consider whether the decoration method requires high heat and, if so, adjust your approach accordingly.

Choosing low-temperature transfers, such as direct-to-film (DTF) or heat-transfer vinyl that applies below 300°F, can significantly reduce the risk of scorching. These transfers are ideal for heat-sensitive fabrics like performance wear, as they allow you to maintain quality without compromising the garment’s integrity.

Use a temperature gun or test strips to see how hot your press is, thereby ensuring your settings are correct. Photo courtesy of STAHLS’ Transfer Express

Pressure settings are another common culprit. Scorching often occurs when the pressure is set too high, especially when using smaller platens where the pressure is concentrated over a smaller surface area. Adjusting the pressure for the platen size can make a significant difference. When in doubt, consult your heat press manufacturer for guidance on fine-tuning your settings.

Testing represents another effective way of preventing scorching. Always test your heat settings, including temperature, pressure and dwell time, on a sample garment or inconspicuous area of a garment you’re planning on decorating before committing to the entire job. Taking the time to test can save you from costly mistakes and wasted materials.

Accessories for Preventing Scorching When Custom Decorating

The right tools and accessories can also play a big role in minimizing scorching. Using silicone cover sheets or upper platen protectors creates a barrier between the heat platen and the garment, which helps prevent direct contact that can lead to press marks or discoloration. Note, not all transfers are compatible with these covers, so it’s important to test how they affect application time and adhesion.

Smaller platens can also be useful for isolating print areas. For example, when applying a left chest logo to a performance polo, using a 6-inch-by-6-inch platen guarantees only the necessary area is exposed to heat, minimizing scorching on the rest of the garment. Heated lower platens, which apply heat from the inside out, are another valuable tool. These are especially helpful when applying dimensional products, like patches or emblems that require high heat and dwell time.

Temperature accuracy is equally important. Using a temperature gun or test strips to check how hot your press is, ensures the actual heat matches the settings, preventing scorching or misapplied transfers.

Troubleshooting Scorching Problems When Custom Decorating

Even with the best preparation, accidents happen. If you find yourself with a scorched garment, though, don’t panic—there are ways to salvage it. Using a small handheld heat press or a household iron on a smooth, flat surface at a low heat setting, for example, can help feather the edges of a press box, creating a softer transition and reducing the mark’s visibility. This technique may not work for every fabric or every level of scorch severity, but it can be a lifesaver in many situations.

It’s critical temperature, pressure and time are all set correctly to ensure your transfers adhere without damaging the underlying material. Photo courtesy of STAHLS’ Hotronix

For light marks or discoloration, spritzing water over the press box can also sometimes restore the garment’s appearance. This is especially the case with cotton T-shirts, where the press box may be due to loss of moisture, not actual scorching.

While not foolproof, these methods offer a way to recover garments that might otherwise be discarded.

Fortunately, advancements in heat printing technology are making it easier than ever to avoid scorching. Low-temperature heat transfers are increasingly popular, providing reliable adhesion without requiring high heat. Additionally, heat presses with smart temperature controls and heated lower platens offer greater precision and consistency, which helps decorators avoid issues caused by fluctuating heat or pressure.

Blank apparel manufacturers are also stepping up by creating heat-resistant options that give decorators more flexibility. These innovations make heat printing even more versatile, allowing decorators to work with a wider range of fabrics and applications.

Key Takeaways to Preventing Scorching When Heat Pressing

• Understanding your materials is crucial to preventing scorching, as different fabrics react to heat in unique ways.
• Adjusting temperature, pressure and time settings ensures that your transfers adhere properly without damaging garments.
• Investing in tools like silicone cover sheets, smaller purpose-built platens and heated lower platens can significantly reduce the risk of scorching.
• Testing your settings on sample garments and checking temperature accuracy with a heat gun or test strips are small steps that can save time and money.

While scorching can feel like a frustrating drawback when heat printing, it’s also an opportunity to showcase the adaptability of this versatile technology. Heat printing stands out as one of the most flexible decoration methods available, capable of accommodating various fabrics, designs, and application needs. By understanding your materials, refining your techniques, and leveraging advancements in technology, you can confidently navigate challenges like scorching and continue delivering professional, high-quality results.

Through proactive measures, attention to detail, and a commitment to learning, you can turn the challenge of scorching into an opportunity to refine your craft and grow your business. 

Dalaney Bradley is a veteran content marketing specialist with long-time custom transfer supplier STAHLS’ Transfer Express (transferexpress.com) and heat-press manufacturer STAHLS’ Hotronix (hotronix.com).

Updated 4/24/25

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