I agree with transfers. Unlimited number of colors, no rejects and gives the transfer workers something to do. Through some shirt fabric over a just applied transfer and hit for a couple of seconds to make it look like it was printed. Did this for Paul Frank for years. Works killer on zippered sweats too. Posted this before, but you can make transfers for the front, the back, the sleeves all over the hoody with just one 24x36 transfer sheet depending on image size. On the zippered side just apply the transfer over the zipper and use hot split transfer inks. As soon as you peel the paper away run a singe edged razor blade down the middle of the transfer to cut it in half and use the zipper to protect the fabric from being cut. Then put some t-shirt material over it and hit it for 3 seconds to help the transfer wrap around near the zipper. Looks like it was a cut piece engineered print and the best part, almost zero rejects compared to 2-4% on a press.
I have a source who makes these transfers daily with powdered adhesives that have excellent wash tests. PM me for his contact info.
Al