The Most Common Source of Delays and Bad Results Is the Artwork File

The single most common source of delays, production problems, and results that do not match expectations in custom apparel is the artwork file. Not the garment. Not the decoration method. The file. And yet it is the step most clients across Orange County think least about because it seems like an administrative detail rather than a craft decision.

At Merchcraft in Santa Ana, we review every artwork file before anything goes into production. For screen printing clients in Costa Mesa, Irvine, and Huntington Beach. For embroidery programs in Newport Beach, Laguna Beach, and throughout OC. Here is what we look for, what causes problems, and how to set up your files so the process moves quickly and the result matches your expectations.

Vector files: why they matter and what they are

A vector file defines artwork using mathematical paths and curves rather than pixels. The critical property of a vector file is that it can be scaled to any size without any loss of quality. A vector logo looks equally sharp at chest embroidery scale and on a 10-foot event banner. A raster (pixel-based) file becomes blurry or pixelated when scaled above its original resolution.

For custom apparel production in Orange County, vector files are preferred for both screen printing and embroidery because they give us the most accurate information about the shapes and colors in your design. File formats we work with most:

• .AI (Adobe Illustrator): The preferred format. If you have an AI file, always start with it
• .EPS (Encapsulated PostScript): Another reliable vector format, equally useful for Orange County screen printing and embroidery programs
• .PDF: Can be vector if exported correctly from a design application. Works well in most cases
• .SVG: Vector format primarily for web, but workable for most apparel applications

If you only have a raster file

Many brands across Orange County, particularly newer businesses and startups in Costa Mesa, Laguna Beach, and Irvine, only have their logo in PNG, JPG, or similar raster formats. This is workable with important caveats.

A high-resolution PNG at 300 dpi or above at the intended print or embroidery size is the most useful raster format for our production process in Santa Ana. A PNG that is 72 dpi and small in pixel dimensions is not usable without significant artwork reconstruction. If your file is low resolution, we can redraw the logo as a vector, which adds time and a redraw cost to the project. It is worth doing once. Every order after that is faster and less expensive because the artwork foundation is solid.

Color specification for screen printing in Orange County

For screen printing programs across OC, each color in your design requires its own screen, and the color count directly affects production cost. When submitting files:

• Specify colors by Pantone (PMS) number wherever possible. For more on how Pantone matching works in screen printing, see our dedicated Pantone matching guide
• Make sure each color is a distinct, separated layer in the file rather than embedded in a flattened raster image
• Avoid gradients in screen printing artwork where possible. Gradients require halftone treatment which changes the visual character of the design
• Review and confirm the color count before finalizing the design. Reducing from four colors to three has a meaningful impact on unit cost at most Orange County production quantities

Color specification for embroidery programs

For embroidery programs in Irvine, Newport Beach, Costa Mesa, and throughout Orange County, color is specified in thread rather than ink. When submitting artwork:

• Provide Pantone numbers if brand color accuracy matters to your program
• Understand that fine lines below a certain width and small text below approximately 0.25 inches may need to be simplified for clean reproduction in thread at production scale
• If you have multiple logo versions, including simplified or single-color versions, share all of them. The simplified version often produces a cleaner embroidery result and we will advise on which is most appropriate

Pre-submission checklist for Orange County apparel orders

• Vector file format preferred (AI, EPS, PDF, SVG)
• If raster only, minimum 300 dpi at intended print or embroidery size
• Fonts outlined or converted to paths (removes font dependency)
• Pantone colors specified where brand accuracy matters
• Separated color layers for screen printing artwork
• Artwork supplied at or close to the intended production size