Exploring 7 Popular Decoration Techniques for Promo Products

3-D foam embroidery makes a strong statement on this mélange trucker mesh-back cap from Counselor Top 40 supplier Cap America.

As I mentioned in the previous installment of Promo Pointers, apparel is the largest category of promotional products, with T-shirts alone making up $4.5 billion – or 17.3% – of overall sales in 2023, according to the 2024 Counselor magazine State of the Industry report. My colleagues at ASI Media and I will be releasing the 2025 report – both in print and online – this summer, complete with fresh numbers for all product categories, but it’s unlikely that apparel’s grip on the industry will have loosened by then.

With that in mind, here’s a look at some of most popular decoration techniques and how they can best be used on promo apparel (plus, a bonus technique at the end ideal for a variety of hard goods).

1. Embroidery: The art of stitching designs into clothing has been around since ancient times, and embroidered designs evoke that history, adding to the perceived value of garments and accessories. It’s a great option for left-chest logos on polo shirts and other corporate apparel. Also consider embroidery for cap designs. Add dimension with puff embroidery – a technique that involves stitching specially digitized designs over a layer of special foam for dramatic effect.
2. Screen Printing: Another technique with a venerated history, screen printing involves transferring an image onto a printed surface by pressing ink through a stenciled screen using a squeegee. It’s often the method of choice for items like concert tees, retail collections and promotional apparel. Where it shines is in its ability to handle high-volume orders cost-efficiently. And though there have been rumblings over the years that newer digital technologies will take over, modern screen-print shops have incorporated various automations and technologies to stay competitive.

The SureColor F9570 dye-sublimation printer from Epson.

3. Dye-sublimation: Dye-sublimation printing works both for apparel and hard goods, as long as they’re made of polyester or coated with a particular polymer for hard goods. The sublimation process involves printing an image on special paper, which is then transferred onto a substrate using a heat press. Unlike with other heat transfers, which sit on the surface of a substrate after being pressed, sublimation dyes transform from a solid to a gas, bonding with the material to create a permanent image. With the right heat press and attachments, decorators can sublimate an array of promo products, including apparel, mugs, tumblers, blankets, towels, flags and banners. One key to remember, however, is that the process is most effective on white or light-colored items.
4. Direct to Garment (DTG): DTG printing involves printing a digital image directly onto apparel and generally requires special pretreatment of garments to ensure that the ink is properly adhered. It allows for photo-quality images without color limitations, but is best for smaller-quantity orders or one-offs. The technique is most effective with cotton or cotton-rich garments.
5. Heat Transfers: With this method, decorators transfer designs onto various surfaces, using heat and pressure. There are a variety of transfer types, including screen-printed transfers and heat transfer vinyl. Heat transfers have become popular because of their versatility and ease of use. Plus, for small runs and custom one-off designs, they can be very cost-effective, since they don’t require extensive setup. Another plus: They allow for on-demand printing and can minimize inventory waste at events.

Fanny pack featuring an UltraColor MAX direct-to-film design from Stahls’.

6. Direct-to-Film (DTF) Transfers: In the last few years, perhaps no other decoration technique has been more talked about than direct-to-film transfers. With DTF, decorators use an inkjet printer to print onto special transfer film, then apply a powder adhesive to the wet ink. The powdered design is then passed under a heat press to cure. Once cured, the design can be transferred to a substrate, using a heat press to melt the adhesive and bond it to the fabric. After pressing, the film is peeled away – leaving a vibrant print. It works well for small, on-demand print runs and can be a good choice for decorating tote bags, apparel, headwear and other items. One note, however, is that DTF prints typically have a “plasticky” hand feel, so a big, blocky print across the front of a T-shirt is likely to be unappealing.

BONUS: Another decorating technique that’s become popular for promotional products (though not for apparel) is UV DTF, which enables decorators to create durable, full-color, peel-and-stick decals by printing designs onto a film using UV-curable inks. Most machines automatically send the film through a built-in laminator, enhancing the look and durability. Unlike with traditional UV digital printing, UV DTF enables decorators to imprint on curved surfaces. UV DTF transfers can be applied on a variety of hard substrates, including plastic, glass, wood and metal.