Plastisol Transfers Cracking?

[mimosatexas]

I do LOTS of plastisol transfers without issues.  I have only had one job kicked back and it was on a strange client supplied jersey material without a tag and I didnt use adhesive powder on that particular job.  I would say I am pretty confident about my process with them.

So I have one client who has now kicked back two small orders (both like 5 shirts) with one color plastisol transfers.  They are cracking around the bottom edges of the letters on 3 lines of text.  Not cracking anywhere else on the design, AND only cracking on 100% cotton (2 out of the 5 in both jobs) but not on the poly cotton blends (3 out of the 5).  I'm stumped.  Any ideas?  Used my standard ink/paper/settings on everything.  Transfers were actually printed in two sets, so not a specific print run issue.

Could she be washing or wearing them in some way where the cotton is causing failure while the blend would not?  She is a fitness instructor so I assume the shirts are being worn and washed more heavily than a standard tee.

[XG Print]

How long is it taking before the cracking starts.  I do not print my own often but the vendor I use is a very respectable one.  I have noticed that after about 5-10 washings on the shirts my daughter has some of them will start to develop a little cracking especially if white is the color of the ink.  If she is a fitness instructor, she may be washing more than normal.  May have to suck it up and direct print on the manual.  I know you don't want to set up the auto for that!! 

[Colin]

Can you post a pic please?

[mimosatexas]

Not certain on the number of times washed, but it seems to be around 2 weeks, so maybe 5 washes?  I have asked, but have not gotten a number from her.

Attached is what she sent.  I have not seen the shirts in person yet.  I could always switch to vinyl or direct print, but I do a lot of these and want to understand what might be the issue so it doesn't pop up again on a larger and more expensive order.

[mimosatexas]

So I just noticed, and it may just be a trick of the angle of the photo, but this text when printed is straight, but it looks pretty stretched/curved here.  For lack of a better way to say it, I wonder if she has a large bust and is stretching the print out.  I could try a stretchier ink next run I guess...

[Frog]

So I just noticed, and it may just be a trick of the angle of the photo, but this text when printed is straight, but it looks pretty stretched/curved here.  For lack of a better way to say it, I wonder if she has a large bust and is stretching the print out.  I could try a stretchier ink next run I guess...

Please have her send a pic while wearing one of these, and we can perhaps even better assess the possible stretch problem.

[mimosatexas]

lol

[XG Print]

Yep!! Looks like major stretching going on...Picture of the client would indeed be helpful in this situation 

[Colin]

The above replies are exactly why I wanted to see a pic of the shirt

Yea, looks like it "got stretched"........

Do double check where her bust line falls within the print area.

[Itsa Little CrOoked]

I was chewing on some coconut flakes, now they are all over my monitor.