Opportunity is missed by most people because it is dressed in overalls and looks like work. - Thomas Edison
there is such little ink coverage that those shirts would go right back to normal after a trip through a clothes dryer.I'd be effing pissed if my boss called me out in front of a customer like that. It's fine to talk about things, but don't throw your employees under the bus. I would never do that to an employee of mine, unless the offense occurred in front of a customer, like cursing or inappropriate language.
The customer was first to point them out, after opening the box and looking at one she noticed it, then decided to go through the entire order in the office while everyone started gathering around wondering what the problem was. I was then "summoned" to the embroidery building and ambushed by the customer, sales person, owner, another sales person, receiving employee and an admin person. I was asked why the print was so distorted, it looked like "a horseshoe shape" and why we didn't catch the problem because there were so many. I had to take a huge breath and stay composed and I tried my best to explain what causes it, why it's really not avoidable in such a small degree that these shirts were and everyone was very surprised that these shirts were a very mild case. It all went in one ear and out the other because the customer did not like them so case closed. I was then confronted again a while later and told that I needed to fix the problem. I told everyone that essentially several hundred thousand shirts have been printed this year that were just like that shirt or worse and that I wasn't just trying to cover my butt by saying it was well within industry standard. I dug through a bunch of prints that were waiting for customer pickup showing there was no difference but due to the design itself, being straight lines that it looked far worse than it was.
What would happen if you flashed, a long flash 2 or 3 heads from the end. This would almost cure the ink and it would have time to cool.It should maintain it's shape when you pull it off.This won't solve your existing problem and I've never tried it but might be an idea for shapes, lines etc that distort when being pulled off the platen.
Did you tell her to go wash the shirts and dry them like her husband would and everything would be fine?