Team shirts look simple until you're the one ordering them. Sizing, deadlines, printing method, and what actually survives a sweaty HIIT session or a HYROX heat all matter more than most people expect. Here's what to know before you order for your gym group, run club, or race team.

Screen print vs. DTF: which one for a small order

Traditional screen printing is efficient at high volumes because each color needs its own screen, but that setup cost doesn't make sense for a 12-shirt gym order. Direct-to-film (DTF) transfers print any design, any number of colors, directly onto a film that's then heat-pressed onto the shirt. For small and mixed-size team orders, DTF usually wins on cost and turnaround, while screen printing still makes sense once you're ordering in bulk with a simple one- or two-color design.

Pick fabric that survives a workout

Cotton is comfortable but holds onto sweat and can feel heavy by the end of a workout. A poly-cotton blend or a moisture-wicking performance tee holds print better under repeated washing and stays lighter during training. If your team is doing anything outdoors in Tucson heat, that difference matters more than it looks on a spec sheet.

Sizing for a group order

Athletic cuts run smaller than standard tees, which catches people off guard on group orders. Order a sample or a size run before committing to 20 or 30 shirts, and build in extra small and extra large sizes since those go first. Set a firm sizing deadline, since custom orders can't easily be resized after printing.

Designing something people will actually wear again

A logo crammed onto a shirt front doesn't hold up over time. Simpler designs, a single accent color, and placement that works on both men's and women's cuts tend to get worn well past the event. If you're outfitting a team for a specific challenge, like HYROX training, consider a design that references the event itself rather than a generic gym logo.

Banners and signage for race day

Beyond shirts, teams often need a banner for a starting line photo, a cheer section, or a booth at a race expo. Vinyl banners hold up outdoors and can be reused season after season if you keep the design generic enough to work for more than one event.

What to bring to your print shop

• Vector art (AI, EPS, or high-resolution PDF) if you have a logo already designed
• A size breakdown for your group, not just a total count
• Your event date, working backward to an order deadline
• Whether you need names or numbers added, which changes the production process

If you're outfitting a team, gym group, or race squad in Tucson, contact Bling by Design for shirts, banners, and signage.