Lane Seven Apparel Archives | Impressions https://impressionsmagazine.com/tag/lane-seven-apparel/ One-Stop Resource for the Decorated Apparel Business Fri, 23 May 2025 17:27:11 +0000 en-US hourly 1 T-Shirt Construction: Spinning, Stitching and Everything in Between https://impressionsmagazine.com/process-technique/t-shirt-construction-spinning-stitching-and-everything-in-between/166052/ https://impressionsmagazine.com/process-technique/t-shirt-construction-spinning-stitching-and-everything-in-between/166052/#respond Thu, 22 May 2025 17:25:21 +0000 https://impressionsmagazine.com/?p=166052 Manufacturing tees blends extensive research, design, systematic production and more to deliver quality, comfort and versatility in one universal garment

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We all love them. We all own way too many of them. You know what I’m talking about: the T-shirt! Now, some people may think of a T-shirt as a very simple thing, but more always meets the eye when it comes to everyone’s favorite go-to apparel. T-shirt craftsmanship involves far more complexity than consumers, and even some decorators, might imagine. The manufacturing process behind a seemingly simple garment is meticulous, requiring deep industry knowledge, innovative techniques and careful attention to detail. Well-renowned experts from leading apparel brands across the industry explain how each step—from initial concept through production and decoration—is essential in crafting high-quality, consumer-friendly sustainable tees.

Concept and Design

The journey to the perfect T-shirt begins long before it reaches retail shelves and wholesale warehouses. It’s a science all beginning with an idea, trend research and analysis.

Lane Seven Apparel T-shirts

Getting the right garment into the hands of the end user is one of the most important sales tools you have. Photos courtesy of Lane Seven

“The products that you see listed in the store or online as new likely began their development process anywhere from nine to 24 months prior,” says Marcus Davis, product manager at Hanesbrands Inc. “The idea typically starts with a team identifying a target market and a price point.”

Adding further depth to this phase, Milissa Gibson, director of sales at Lane Seven Apparel, says the design process can be as easy or complicated as you want to make it, but it will all come down to finding the ideal niche for a specific market. Echoing Davis, Gibson says “It always starts with an idea or concept, like a mood board, often taking elements from one design and combining it with another.”

This can then help determine what fabrics will be considered, where the product will be made, and what features and benefits should be included. Once those details have been narrowed, then a team will work on designing what the tee will look like, create patterns and begin fabric development for prototype samples.

“The first step in a new style is design,” says Jakob Daito, president and co-founder of US Standard Apparel.  “A mood board is created to inspire a direction, oftentimes based on vintage references. Once the idea takes form, the concept is passed to the tech and pattern team who digitizes the pattern. This pattern is then shared with the sample department to cut and sew the initial samples for fitting.”

It’s all about what the consumer wants at a specific time, so research is fundamental explains Jen Oleksik, vice president of apparel of Live & Tell Apparel by L.A.T. “Looking at fabrics, fits, details and decoration trends are all key factors in building out a T-shirt before you even begin designing. From there, it’s landing on a fabric, making sure your T-shirt specs are the perfect fit, and in our industry, making sure it’s easy to decorate across various techniques.”

Fabric Selection

Choosing the right fabric is crucial. Whether the fabric type is created in-house or sourced across third-party suppliers, it must measure up to the aforementioned qualities. Otherwise, the final product will be futile setting the process back not only in time but money as well.

ToTheMarket_Dehradun-india-raw-cotton

The T-shirt process starts with fiber selection. Whether it’s organic cotton, recycled polyester or a performance blend impacts durability, comfort and sustainability. Photo courtesy of TO THE MARKET

“Fiber selection impacts durability, comfort, and sustainability,” says Mehathab Joharullah, TO THE MARKET’s compliance and impact analyst. “Fibers are spun into yarn, which is knit into fabric [jersey being the most common for T-shirts]. After knitting, the fabric undergoes pre-treatment processes, like dyeing, softening and sometimes enzyme washing for a soft, worn-in hand feel.”

Mel Lay, co-founder of Allmade Apparel, elaborates, “Once the yarn is ready, the next step is to weave or knit the fabric. In the case of Allmade Apparel, we focus on creating a fabric that’s soft, durable and breathable, perfect for everyday wear or custom decoration.”

Oleksik notes that consumer preferences must also be taken into account during fabric selection, noting, “Higher quality, combed ring-spun cotton garments can look and feel better and ultimately decorate nicer.”

Fabric weight, measured in grams per square meter (GSM), can determine durability, weight and feel, says Joharullah. “Lighter weights (120-150 GSM) are airy and ideal for layering, but can be sheer and have lower tear strength. Midweight fabrics (160-180 GSM) offer the best balance of comfort and structure, making them the industry favorite, while heavyweights (200+ GSM) provide extra durability, more structure and warmth—ideal for long sleeves, lightweight sweatshirts or rugby style polos, for example.”

Garment Construction

Textile manufacturers employ different types of equipment to knit the selected fabrics for T-shirts, with certain machines being more prevalent in either the Eastern or Western hemisphere. The type of equipment used usually depends on the preferred construction method. There are two primary construction methods: tubular and side-seamed.

“Tubular tees, or tees without any seams on the side of the body, are made from machines that knit the fabric in a tube, much like a sock,” explains Davis. “The size of the tee is determined by how wide the tube of fabric is knit. Other machines can knit fabrics in a single-ply sheet, which is known as an open width fabric. Because the fabric is knit single-ply, the tee made from this fabric will end up with seams where the body was assembled. Side-seamed garments can be made from tubular knit fabrics that have been cut, but you can’t make a tubular tee from open width fabric.”

Gibson points out the economic advantage of tubular garments, which are knit in a continuous tube, but also mentions, “Side-seam shirts lead to a much more elevated fit and overall product.”

LAT Apparel female model wears T-shirt

The relaxed, lived-in look and feel of the Ladies Vintage Wash Tee never goes out of style. Photo courtesy of LAT Apparel

The key benefit to a tubular garment versus a “regular” or side-seamed tee, would be a lower cost, Oleksik agrees. “However, the benefits of a side-seamed tee are more in quality and performance. Side seams aid in a better fit and less torque when washing.”

Utilizing side-seam construction will significantly enhance the wearability of a T-shirt, providing a more tailored fit that better aligns with all body types, while reducing twisting and distortion after washing.

“Side-seamed T-shirts offer better fit and reduce fabric waste, despite higher costs,” Joharullah says. “Once prepared, the fabric is cut into pieces like a puzzle according to the design specifications for the perfect fit, stitched together using specialized sewing techniques, and finished with details like ribbed necklines, reinforced seams, or double-stitched hems for the best quality possible.”

Lay also supports side-seamed construction for its quality advantages: “We love for our products to be categorized into the fashion-fit category, offering a more flattering silhouette.”

Attention to Detail

In addition to fabric consistency, quality T-shirt production hinges on precise stitching and finishing. According to Oleksik, higher-quality garments typically feature “double-needle stitching or cover stitches, enhancing durability.”

Sewing a T-shirt

From the beginning, precision is paramount. Photo courtesy of Hanesbrands

When evaluating the quality of a T-shirt, Davis suggests one of the first things you should be on the lookout for is noticeable puckering and/or waviness around the seams. This is typically the result of too much or not enough tension on the fabric when sewing. “Another easy thing to identify is whether there are any broken or popped stitches,” he says. “This could result in seams coming apart after washing and wearing.”

Gibson emphasizes how much details matter. “Look at sewing hems—extra fabric, loose threads, single or double-needle stitches—these indicate the garment’s quality.”

For its part, Allmade uses reinforced stitching in critical areas like the shoulder and arm seams to prevent unraveling over time, further evidence of the importance of this aspect of T-shirt production.

“We sew using tee manufacturing, where each operator constructs a single portion of the garment in rapid succession,” says Marty Bailey, US Standard Apparel president of manufacturing. “The components are moved through the line until the finished garment takes form, a QC at the end of each line triple checks for any defects or issues.”

Once construction is complete, it is vital each T-shirt undergoes quality control checks before being pressed, folded and packaged for distribution. Joharullah explains that each step requires precision—especially when balancing softness, strength and sustainability.

Sustainability Practices

Sustainability remains a critical aspect of modern apparel production. There is a growing global demand for sustainable manufacturing practices that stress environmental responsibility at every stage—beginning at the seed level. This shift reflects a more conscious consumer base and stricter

Allmade honduras factory

Allmade prioritizes eco-friendly materials above all. Photo courtesy of Allmade

regulatory landscapes. Europe is at the forefront of this movement, setting standards that drive the market through both legislative requirements and strong consumer preferences for ethically produced, eco-friendly apparel. However, U.S. manufacturers have now made sustainability a priority as well.

Describing HanesBrands’ sustainability efforts, for example, Davis says, “75 percent of [HanesBrands’] cotton is grown in the U.S. by farmers using leading environmental practices. Nearly 59 percent of our electricity comes from renewable sources, and we’re committed to reducing packaging waste significantly by 2025.”

Similarly, at Allmade sustainability is central to the company’s fabric choices, which include fabrics made from materials like organic cotton, recycled polyester and modal. “Allmade’s dedication to sustainability is to continuously prioritize eco-friendly materials and eco-conscious manufacturing processes, minimizing waste, using water-based inks and reducing carbon emissions,” Lay says.

Joharullah stresses that true sustainability extends beyond fabric: “Sustainable materials are just the baseline. True sustainability examines the manufacturing process itself—energy and water usage, waste monitoring, carbon reduction, and ethical labor practices.”

One thing is clear, manufacturers worldwide are being challenged—and incentivized—to reimagine their production models to meet these fast-evolving expectations.

Allmade honduras factory

Selected materials are spun into yarn, which creates the foundation of the fabric. Photo courtesy of Allmade

“At Live and Tell Apparel, we have a sustainability team that works to ensure we are making a conscious effort to not only improve sustainability in our manufacturing, but also in our daily operations,” Oleksik says. “Our sustainable products such as the 6901ECO tee blends 60-percent organic cotton and 40-percent recycled polyester. We are also currently implementing some new processes that will greatly reduce our sampling needs while improving our speed to market.”

“You are seeing major advancements in regenerated and recycled materials and costs coming down; sometimes it’s even less expensive for products [like our LS18002 Future Fleece made from 100-percent regenerated yarn] to be made from either regenerated or recycled materials than a standard garment,” says Gibson.

“A truly sustainable T-shirt isn’t only about what it’s made from—it’s about how it’s made,” says Joharullah.

Decoration and Compatibility

Fabric choice, construction and sustainability are not the only factors manufacturers consider during the production process. Apparel decorators and the challenges they often face are also at the very forefront of T-shirt design, a surprisingly complex problem Davis acknowledges the industry is still working to master. “It’s difficult to create one perfect T-shirt for all decorating methods. Direct-to-film (DTF) printing helps solve compatibility issues, but fabric content still significantly impacts decoration.”

Oleksik notes there can also be limitations with textured fabrics. Lower quality fabrics can pill or shed as well, further complicating decoration. She says to stay vigilant as thorough testing during the development process can prevent these issues.

Addressing decoration-specific difficulties, Gibson says certain printing techniques like sublimation or direct-to-garment (DTG) require specific fabric compositions, but advancements in print technology have expanded compatibility.

HanesBrands T-shirt

Tees with the least amount of sewing are the most production friendly. Photo courtesy of Hanesbrands

As printing technologies continue to advance and new methods emerge, the definition of the ideal T-shirt must also adapt—evolving in fabric, construction and compatibility to meet the changing needs of decorators.

“Fortunately, DTF printing has solved some of these issues as this printing technique appears to be compatible with a very wide range of fabric types,” Davis says. “This may be an instance where the decorators have actually found a solution to the challenge. If decorators have a printing technique that works on all tees, then they are no longer limited to what options they have when choosing a tee to decorate on.”

That said, until the holy grail of T-shirts is invented, Lay says it is important for companies like Allmade to offer a variety of fabric options which work well with digital decorating, screen printing, heat transfer and embroidery to ensure decorators can find the right T-shirt for their needs.

“While no single T-shirt is perfect for every decorating method, sourcing a high-quality midweight, tightly knit product, like the Global Good classic organic blend tee, is a universal option,” offers Joharullah.

Fabrics such as these can balance absorbency for screen printing, smoothness for DTG and durability for embroidery. Adding a bit of recycled polyester checks nearly all the boxes. It enhances performance, maintains print versatility and is eco-conscious. All specifics consumers and decorators love.

Influence of Decorated Apparel Market

The decorated apparel industry plays a pivotal role in shaping production trends, as manufacturers will continue to tailor their offerings to meet the specific needs of decorators. Joharullah notes, “The decorated-apparel market demands specific fabric blends, stitch types and fits based on printing needs. Consumers drive demands and manufacturers must adapt. Trends are co-created—brands introduce new innovations and consumers decide what sticks.”

Gibson highlights Lane Seven Apparel’s proactive approach as well, saying, “Our focus is the decorated-apparel market, ensuring our garments can handle a variety of decoration methods with the latest technology.”

US Standard Apparel 1551 Tee

USSA’s Standard SS Tee is knit, cut, sewn and dyed in Los Angeles. Photo courtesy of US Standard Apparel.

These production shifts are driven by a dynamic interplay between consumer behavior and brand innovation. “Trends often start with consumers,” says Davis. “Small shifts in buying habits prompt manufacturers to adjust product offerings, like the recent shift toward heavier-weight tees.” Gibson also points to music merchandise as a powerful trend driver: “Music merch is setting trends. Leading artists’ collections often predict broader market shifts.”

Tapping into the music influence, US Standard Apparel is connecting directly with the consumer via social media. The brand recently launched its “Birth of a Shirt” series on Instagram, giving consumers an inside look at how their Vintage Rocker Tee is made. The multi-video series provides an in-depth, behind-the-scenes look of the manufacturing process, which in turn invites consumers to be part of the conversation.

Oleksik adds that along with broader market shifts, societal forces are also at play furthering the conversation as well: “Trends emerge from a mix of technology, social, environmental factors, economics, and even politics, shaping consumer preferences globally.”

Ultimately, creating the perfect T-shirt is the result of thoughtful collaboration across all stages of production—from fiber selection and fabric development to stitching, sustainability and market alignment. As the industry evolves, open dialogue between manufacturers, decorators, and consumers will continue to ensure that T-shirts remain everyone’s favorite apparel.

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Blank Tees are 2025’s Heavyweight Champs for Custom Decorators https://impressionsmagazine.com/trends/tees-are-2025s-heavyweight-champs/165123/ https://impressionsmagazine.com/trends/tees-are-2025s-heavyweight-champs/165123/#respond Mon, 17 Feb 2025 18:06:12 +0000 https://impressionsmagazine.com/?p=165123 Always ready for the ring, the ultimate clothing staple is set to be a knockout for the year

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If the basic T-shirt for 2025 has any dominant descriptors, they would be: “oversized” and “relaxed,” both of which derive in part from “’90s streetwear,” another 2025 trend for tees. Another is “heavyweight” or at least, “heavier weight.” Other buzzwords that encapsulate anticipated 2025 T-shirt trends are “sustainable, boxy and neutral.”

A selection of representatives from apparel companies weighed in on upcoming trends, including Marcus Davis, product manager with Hanesbrands, who said, “Tees are expected to continue to follow the macro trends that we’ve been seeing in recent years, such as designs inspired by the ’90s or materials focused on sustainability. Probably one of the fastest growing segments in the market are tees made with heavyweight fabrics, which I would categorize as being six ounces or heavier.”

Jen Oleksik, vice president of apparel for LAT Apparel, elaborated, “The basic tee will continue to be defined by fit, fabric, and quality. With so many options in the market, it is important to stand out with key differentiators. A consistent and well-fitting tee is a must. Fabric should not only be soft but also decorate easily. Quality encompasses the other two key factors, but also includes construction details, durability of the product, consistency of color and beyond.”

Milissa Gibson, sales director with Lane Seven Apparel, pointed to the merging of T-shirt categories in recent years. “For the last 15-20 years, the basic tee has fallen into one of two categories—a fashion basic and a staple commodity price-point-driven tee. Now, what was once considered fashion is becoming more in that commodity basic. You’re seeing the transition go from a lightweight to heavyweight,” she said.

“People will look for timeless pieces that easily fit into their everyday lives and don’t add to waste. Expect terms like conscious consumption, carbon-neutral, and eco-innovation to dominate the conversation,” added Katy Mendoza, creative director at Threadfast Apparel.

T-shirt male model Hanes Beefy-T

The Beefy Tee (5180R) has set the standard for more than 45 years. Photo courtesy of Hanes

Weight and See: Heavyweight T-shirts in Vogue

Virtually everyone who chimed in said that heavyweight T-shirts are coming back into vogue. “We’ve been seeing increasing focus on the “heavy tee” as being a new standard of ‘dressed up casual,’ and it makes sense,” says Ryan Zaczynski, founder and CEO of Maison Tiet Ltd. “Super thin tees, while comfortable, often lack durability and honestly aren’t very forgiving on many body types. Having a bit more weight to the material helps with durability, and with the right cut it has a more forgiving drape.”

Oleksik agreed about the heavier-weight fabrics, adding that they are emerging from the streetwear influence.

“The Hanes Beefy-T was actually at the start of this trend in 1975 when it was introduced as the first heavyweight tee in the print wear market. The recent attention to these heavier weight tees is fitting as the Beefy-T will be celebrating its 50th anniversary in 2025,” Davis said.

Comfort is King: Silhouettes and Fabrics/Fabric Blends

Whether it’s an after-effect of the pandemic or a subconscious need to be and feel comfortable due to the stresses of life, casual styles are trending toward “relaxed,” a holdover from previous years; a trend that began in the women’s market but is making its way to the men’s and youth markets, Oleksik noted, with boxier and cropped cuts still influencing the market.

Victoria Novosel, director of marketing at Bella+Canvas, agreed, adding, “Streetwear and cropped or fitted women’s silhouettes are still seen everywhere at retail, so we do expect that trend to continue into the wholesale market.”

BELLA+CANVAS female model T-shirt

The Unisex Heavyweight Tee (4610) in Athletic Heather. Photo courtesy of BELLA+CANVAS

Oversized tees also continue to be in strong demand. Oversized fits, like relaxed fits, are all elements of what is comfortable. “It’s tough to go back to garments that might not be as loose and comfortable simply for the sake of fashion,” said Zaczynski. “Styling our oversized Cali Relaxed fit with outfits that go beyond sweats or jeans is something that has been cool to see. You wouldn’t think an oversized tee would be a likely pairing with a maxi skirt, but one of our customers on TikTok has made this look part of their regular rotation!”

Zaczynski is banking on the next generation of consumers that will come to support and understand the quality and value of hemp, despite the misperception that hemp is a rough and scratchy material. “Hemp textiles are almost always offered as a blend, so it will never displace cotton. Hemp blended with cotton or poly yarn produces unbelievably comfy, breathable knits that will wear well for years due to hemp’s exceptional durability, and it’s our mission to get this information out into the world,” he said.

One of the reasons that oversized and relaxed fits are popular is that they allow for layering. “Styles influenced by the ’90s will continue but expect classic silhouettes to be the biggest winners as consumers are looking for longevity in what they are wearing as a value for their money. Classic short sleeve and long sleeve tees will always be a staple to many people. Fast fashion items are no longer as popular due to how quickly they look dated,” said Marcus.

“In 2025, relaxed fits and drop shoulders will continue to dominate across men’s, women’s, and youth styles, driven by the streetwear and athleisure trends. Oversized silhouettes and boxy tees will remain essential for their comfort and versatility, with crop tops still trending among younger audiences,” said Mendoza.

What Goes Around Comes Around with Blank T-shirt Styles

T-shirt styles will be going up a notch, with the basic tee having a place in fashion and the ’90s increasingly back in vogue.

There is also a continued place for vintage looks, such as LAT Apparel’s introduction of its Vintage Wash collection, a trend that is not expected to wane any time soon.

“Society continues to look to the past to inform the present and inspire the future. In recent years our use of ‘vintage’ has been in reference to silhouettes and cuts of different products, but as we move into 2025, we’re seeing an even deeper influence in ‘vintage’ color. So maybe it’s a more modern silhouette with a worn or vintage look due to the way the product is dyed or the shade of the color standard,” said Novosel of her company’s perspective on vintage.

Influences: How T-shirts Got where they are Today

As in previous years, T-shirt design is influenced by many demographics and styles, but with the advent of social media and its ability to reach wider

Models in heavyweight T-shirts Threadfast Apparel

The Epic Unisex Tee (T1000) shown in Maroon Heather. Photo courtesy of Threadfast Apparel

audiences, fashion in general has become more universal. “Specifically in the ladies’ category, women are finding more confidence and excitement in wearing what they love no matter their size, shape, or age,” said Oleksik. “Online consumers are greatly driving new development, especially from a fit standpoint. More consumers than ever are purchasing apparel online. By offering a fit that is consistent, thoughtful and on-trend, it limits the number of returns and gives buyers confidence in the product purchase.”

For her part, Gibson said that the demographics that are having the most influence on T-shirt design and style is skewing younger and younger. By way of example, she said, “You’re seeing oversized, boxy fits trend at retail that are driven by the younger, Millennial Gen X, and you’re starting to see Gen Alpha’s influence on the fit.”

Most manufacturers agreed that streetwear is still a major influence on T-shirt styles, a resurrection from the ’90s, and accounts for the relaxed and oversized fits seen today.

“Streetwear has an influence on every generation, and we don’t anticipate that letting up,” said Zaczynski. “But we do hear whispers about streetwear fashion finally becoming a bit fatigued with the standard uniform of jersey knits and fleece—button up oxfords and other preppier garments are something we think will get an increasing amount of play in the coming seasons.”

Sustainability: Apparel Decorators and Customers Crave Eco-Friendly

Customers are seeking transparency in what they consume and what they wear, from where materials are sourced to how and where garments are being manufactured. While sustainability may have been a newfangled idea some years ago, many of today’s consumers are practically demanding it, and manufacturers are responding. The wholesale channel is gradually catching up.

“I believe the industry is doing what it can to address concerns around, not just environmental issues, but also those of corporate responsibility,” said Novosel. “Bella+Canvas has an internal committee that meets regularly to ensure we continue to push these boundaries and efforts.”

Likewise, Threadfast has developed initiatives like Better Cotton membership, U.S.-grown cotton sourcing and recycled polyester. “Through our Plant with Threadfast program, we plant a tree for every case sold, helping offset our carbon footprint and support communities impacted by forest fires,” said Mendoza. “That said, there’s more room to grow. We need to see wider adoption of certifications like WRAP and OEKO-TEX to meet evolving consumer expectations.”

Male model in T-shirt LAT Apparel

The Unisex Bamboo Tee has a soft feel. Photo courtesy of LAT Apparel

LAT Apparel has two new styles for 2025 that are environmentally friendly: first, its 6901ECO is a blend of 60-percent Combed Ringspun Organic Cotton and 40-percent Post-Consumer Recycled Polyester; second, the 6904 uses 70-percent Viscose from Bamboo and 30-percent Combed Ringspun Organic Cotton. “Bamboo-derived fabric is not only incredibly soft and comfortable to wear but also sustainably grown, making it a responsibly sourced choice,” said Oleksik.

Hanes also offers Hanes EcoSmart polyester, part of the Hanes EcoSmart cotton and polyester blended tees and in the Hanes Perfect Tri-Blend tees collections. “EcoSmart polyester is a technology that allows synthetic plastic-based fibers to behave more like natural fibers once they are in a landfill as compared to untreated polyester,” said Davis. “This technology significantly accelerates the breakdown of plastic fibers in the soil and sea, which is then reducing the impact of microplastic waste.”

It’s all in the name at Toasty Hemp Co, a brand of Maison Tiet Ltd., which focuses on utilizing hemp, a durable and lightweight fabric ideal for T-shirts that is environmentally friendly. “Hemp is an incredibly sustainable material that exceeds expectations in terms of quality, comfort, and durability, along with it having amazing performance attributes such as superior thermoregulation and natural resistance to odors,” said Zaczynski. “It really is a wonder material, but for the past 40-plus years the communication of these amazing qualities hasn’t effectively landed—yet!—with wholesale buyers and end consumers.”

“Hemp textiles are almost always offered as a blend, so it will never displace cotton. Rather, it is a supplemental ingredient that will help to shift the overall supply chain to improving the composition (and quality) of all garments in the coming years,” he added.

Colors and Textures: Neutrals, Warm Grays, Earthy Palettes

Everyone agrees that neutrals will continue to rise in popularity. “Neutrals continue to dominate, but with more modern spins like warm grays and earthy palettes,” said Oleksik. “In terms of trend forecasting, you should begin to see a reemergence of jewel tones, specifically in the blue and green tones.”

“Expect earth tones like sandstone and clay to lead, mirroring the sustainability movement. But there will also be room for vibrant colors like lagoon blue and orchid, perfect for adding life to resort and lifestyle collections,” agreed Mendoza.

In addition to vibrant blues and greens, others said that darker, bolder hues are going to see the light of day.

Regarding texture, especially in the wholesale market, Oleksik said it’s more about a texture that offers visual value but is easy to decorate, like heathering or washed fabrics. Similarly, Gibson suggested two by one or one by one ribbing and micro ribbing will be big trends, especially in the women’s’ market and on the wholesale side.

T-Shirt Technology, the role of Direct-to-Film (DTF) and Direct-to-Garment (DTF)

Sublimation, screen printing and direct-to-garment printing have been tried and true printing methods for traditional T-shirt fabrics, but direct-to-film (DTF) is becoming more popular in the market for smaller quantities and quick turnover for customization. Oleksik observed that sublimation, a decorating

Toasty Hemp Co. T-shirt

Toasty’s hemp tees keep their shape after wash and wear. Photo courtesy of Toasty Hemp Co.

technology that dominated for years and is still relevant in the wholesale channels, has shifted to more of a home crafter market. Her company, LAT Apparel, will not only test fabrics during the development stages but will include print recommendations and techniques to their customers. “We always try to maximize the amount of print techniques available for our fabrics. For instance, our fleece products are elevated with a 3-end fleece that has a 100-percent cotton face which allows for a smooth decoration surface that most other fleece in the market does not offer,” Oleksik said.

The type of fabric, of course, makes a difference, with DTG being ideal for cotton, and polyester blends better for sublimation and DTF, agreed Mendoza.

Hemp, however, is a new frontier for most decorators, and Zaczynski said that his company is always learning something new, often having to be the being the first to pioneer decorating methods, which he said is both terrifying and exciting.

“For us in hemp, it feels like we will be developing new tee technology in real time in 2025—it’s going to be a huge R&D year. We’ve only begun to scratch the surface with respect to hemp’s potential, and developing the technology to produce unique blends is as important as imagining new designs and silhouettes for this amazing material. Decoration is most definitely a form of art, but for us it’s also very much a science because we’re having to define many of the techniques and standards that we’ll eventually be communicating to our industry partners.”

Threadfast, too, is looking into innovative, eco-friendly treatments that reduce water usage to align with the company’s sustainability goals. “Threadfast also has innovated by creating the only NFC enabled t-shirt in the industry which holds an NFC chip on its sleeve that can be programmed to any digital content the customer needs,” said Mendoza.

What to Expect in the Future with T-shirt Design and Custom Decorating

Toasty Hemp has been working with collaborators in Pakistan to develop a new supply chain for hemp fabrics, as that country has recently legalized the cultivation of industrial hemp.

“For 2025, we are excited about releasing our own takes on classic hemp blends, and also some experimental new blends that the world has never previously seen from hemp,” said Zaczynski.

The desire for sustainability is only going to expand as the years go by. “New laws are also driving companies to adjust their priorities to stay compliant in the regions they are selling in,” said Davis, noting that new laws on the books in some states are outlining the ways in which companies should keep their products out of landfills and are regulating how companies should disclose greenhouse gas emissions. “Because of these things, the delay between the retail and wholesale channels has disappeared.”

Hilary Daninhirsch is an award-winning freelance writer based in Pittsburgh. Her work has been featured in a number of lifestyle and trade magazines. She can be reached at hdaninhirsch@gmail.com or hilarydaninhirsch.journoportfolio.com.

Updated 4/24/25

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