Discharge wrap around on 500 black tees

[Rockers]

How to do this best. 500 tees all black, 5 different sizes. They want this to look neat where the image will join.   

[Action1]

How to do this best. 500 tees all black, 5 different sizes. They want this to look neat where the image will join.

Convince them to take a shirt that is not as perfectly registered between the front and back as they would like. Make the wrap image one that's not a solid stripe and will mask imperfection. The order volume doesn't warrant the investment in wrap around flip pallets. Therefore, you are left with laying the shirt on top of the pallet. Prepare the shirts first. Use an overhead laser alignment system or alternative for shirt positioning.

[tonypep]

This is a setup for failure. Customer most likely will have high expectations beyond what is reasonable.
Not impossible but most likely not worth the time and effort to make it successful. First; the left chest and full back need to be printed separately, making this a four hit decoration. For the hem prints you would need to lay the shirts flat on a platen app 30" wide. Spray the inside of shirt with cornstarch tack or light adhesive from a craft store. Start with the largest shirt size and tape out image as you go. As Eric suggests, "lasers" are a good option however; assuming the customer wants the image placement the same on all sizes, accurately drawn lines should be sufficient. Discharge is the best option as a white/flash/white not really an option. Even if you had a flash that wide there is a reasonable expectation that shirt will move causing mis registration. Expect higher than normal falloutand most importantly price accordingly. Personally I would not take the job unless it was cut and sew.

[mimosatexas]

definitely cut and sew or it isn't going to happen without changes to the art and a lot of labor.

[abchung]

It is doing able for weaved fabrics but not for knitted fabrics.

Knitted fabrics can stretch and shrinks, and to align it on the sewing machine will not be economical.

[Homer]

thinking out loud here but what if you made a large scale bottle printer. take a big garbage can or something,  stretch a shirt on, turn it on it's side, roll the can while the screen stays stationary...somehow..lots of d*cking around but if I was backed into a corner, I'd roll that way....not on 500+ shirts though, yikes..

[Screened Gear]

Do not walk from this job...Run. It is not gong to work unless you get creative. The repeating pattern has to be the exact length of the tubed fabric per size or it will not line up. Even if you figured out the exact length for the large shirt you would have to rely on the manufacture to get shirts that are all the same. We all know that could never happen. Then you have the stretching part, you can't control that.

Since both sides have to match up perfectly a flip pallet will not help.

Lasers would not be accurate enough.

I have done some designs that wrapped around the shirt that had 2 designs that matched up. I would never take on a job that needed both sides of the design to meet and align.

On this job I would charge atleast the cost of the shirt as a PITA fee. This way you can cover all your loss and still make what you want to. You should make good money on this job. You maybe the only one that will do it.

If I was going to do this this is how I would try.

You would need a screen for each front side. and two screens of the back side. I would do one set for every two sizes. (I know wait on why) So your looking at 12 screen for 4 sizes of shirts. You will need emulsion that is easily seen though. (the first back screen only. Maybe only coat it 1/1) This will make lining up a lot easier. What your going to do is print the first side but you want to place the shirt on the boards and stretch the fabric to your half way marks. By doing this you eliminate any imperfections in the shirt sizes. You will need to add about a inch to what you think the widest shirt will be. Yes it will distort the design slightly but that is fine they will not notice one inch of stretch over 20 inches. Print them all up and then you print the back print like this. You make 2 screens for the back print. One will not have ink in it. This is your alignment screen. You will put the shirt on the board and then lower the screen. You will stretch and pull the shirt under the screen until you get it perfect. Then push the shirt down so it stays in place. Your next screen will be perfectly registered to this screen so when you print it it will be perfect.  The reason you want a clean screen is because this way you will not have ink transferring onto the shirt when your trying to align it and you can push the shirt down while the screen is down.

That is really it. You are going to hate doing it so make sure to charge alot.

[Screened Gear]

Just a heads up you will need the ability to print at least a 27 inch print for a 2X

[GraphicDisorder]

The fact the size of each shirt changes and isn't consistent will make this near impossible if you want it perfect.  I would run.  Quickly.  It's likely the expectations are unrealistic. 

[Rockers]

Thanks guys, I had the same thought as most of you to run. So I convinced the client to do only one side and as well a little smaller. They understood.

[Screened Gear]

Thanks guys, I had the same thought as most of you to run. So I convinced the client to do only one side and as well a little smaller. They understood.

I think you did the right thing. The only reason I take some of those jobs is because I like the challenge. I would never take one that was 500 shirts.

[kingscreen]

How about "no"?