Screen Printing Process Explained: From Design to Delivery

If you’ve ever ordered custom t-shirts, you’ve probably wondered:

👉 What actually happens after I place my order?

From your first idea to the moment your shirts arrive, there’s a full process happening behind the scenes — and it plays a big role in how your final product turns out.

At Sunday Cool, we’ve built our entire system around making that process simple, fast, and enjoyable — while still delivering high-quality, super-soft custom apparel.

Here’s what the screen printing process looks like from start to finish.

Learn how the screen printing process works from start to finish. Discover how custom t-shirts are made with design, printing, and fast turnaround.

Screen Printing Process Explained: From Design to Delivery

Step 1: It Starts With a Conversation

Every great shirt starts with understanding the bigger picture.

When you begin your order, you’re connected with a Project Advisor who helps guide the entire process.

This isn’t just about placing an order.

It’s about figuring out:

  • what your shirts are for
  • when you need them
  • how many you need
  • what your vision looks like

Because before anything gets printed, the goal is to make sure everything is aligned from the start.

Step 2: Turning Your Idea Into a Design

Not everyone comes in with a finished design.

And that’s completely fine.

Whether you have:

  • a rough idea
  • a sketch
  • or a fully built design

Sunday Cool’s in-house artists take that starting point and turn it into something ready for print.

We also offer a full library of customizable design templates that might be exactly what you’re looking for.

You can start with a template and adjust any part of the design to fit your vision — from text and layout to colors and details.

Because great shirts don’t just look good on a screen — they’re designed to print well on fabric.

Step 3: Preparing the Screen (Where Printing Begins)

This is where things shift from digital to physical.

Screen printing uses a mesh screen and a stencil to transfer ink onto fabric — one color at a time.

At Sunday Cool, this process involves:

  • coating screens with a light-sensitive emulsion
  • exposing the design using UV light
  • washing out the stencil
  • preparing the screen for printing

This step is what allows your design to be printed clean, consistent, and repeatable across every shirt.

Step 4: Printing the Shirts

Now the design comes to life.

Ink is pushed through the screen onto the shirt, layer by layer, building the final design.

This is where quality really shows.

At Sunday Cool, printing focuses on:

  • Super-Soft Ink (water-based screen printing) for lightweight, breathable prints
  • precision and consistency across every shirt
  • designs that feel like part of the fabric — not sitting on top

And if you want to take things further, this is where specialty inks come in:

These details turn a shirt into something interactive — something people remember.

Step 5: Quality Check and Finishing

Once printing is complete, every order goes through a quality check.

This ensures:

  • prints are clean and accurate
  • colors match expectations
  • shirts meet quality standards

Because consistency matters — especially when you’re ordering for a full group.

Step 6: Fast Turnaround and Delivery

After everything is printed and checked, your order is packed and shipped.

At Sunday Cool, orders ship within 72 hours of art approval, helping you stay on track even when timelines are tight.

That means:

  • less waiting
  • fewer delays
  • more confidence your shirts will arrive when you need them

Why the Process Matters

Not all screen printing processes are built the same.

And the difference shows up in the final product.

A strong process leads to:

  • better feeling shirts
  • longer-lasting prints
  • fewer surprises
  • and a smoother experience overall

Because at the end of the day…

It’s not just about how a shirt is printed.

It’s about how it feels when someone puts it on.

More Than Just Printing

Screen printing is the method.

But what you’re really creating is something bigger.

Custom apparel becomes part of:

  • your event
  • your message
  • your community

And when everything comes together — design, print, feel, and fit — it becomes something people actually want to wear.

Ready to Get Started?

If you’re ready to create custom t-shirts with a process that’s built for quality, speed, and real-world use, we’d love to help.

👉 Start your custom order HERE

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The Ultimate Church Merch Calendar: What to Order and When

Plan your church's merch calendar year-round. From VBS to holiday events, learn what to order, when to order it, and which products fit each season.

Spring: VBS Season

VBS is one of the biggest and most predictable merch pushes of the year — which also means it's one of the easiest to plan for well in advance.

The key with VBS is designing around your curriculum theme rather than something generic. Whether your church runs curriculum from Lifeway, Group, Orange, or another publisher, we've built shirt idea guides tailored to specific themes each year — worth a search on our blog once your VBS theme is confirmed.

What tends to work best for VBS:

Start planning: 8–10 weeks before your VBS week.

Early Summer: Summer Camp

Summer camp shirts have a way of sneaking up, since camp planning tends to compete with everything else on the calendar for attention. If you haven't already, our summer camp shirt guide and complete ordering guide walk through design ideas and a full ordering timeline.

What tends to work best for camp:

  • Super-Soft Tee, built to hold up through a full week of outdoor activity
  • Vintage badge or nature-inspired graphics for a classic camp feel
  • Specialty inks like Sun Reveal Ink for outdoor reveal moments

Start planning: 10–12 weeks before camp.

Late Summer: Back to School

Back to school is a short window with a hard deadline — school start dates don't move. Our back to school shirt guide covers design and timing in detail.

What tends to work best:

  • Super-Soft Tee or Oversized Boxy Tee for a current, wearable look kids will actually take to school
  • A clean, logo-forward design that doesn't read as "churchy merch"
  • Sunday Cool's Take Note Express Package — a shirt, sticker, and notebook bundle built specifically for this season

Start planning: 4–6 weeks before the first day of school.

Fall: Ministry Kickoff Season

Kickoff season overlaps with back to school, but it's its own moment — the start of a new ministry year, not just a new school year. Our ministry kickoff shirt guide and Build Your Brand guide both dig into this in depth.

What tends to work best:

  • A design tied to your whole season's theme, not just kickoff night
  • Super-Soft Crewneck for a slightly more polished leader/volunteer look
  • A full Build Your Brand bundle to create cohesion across shirts, stickers, and handouts from day one

Start planning: 4–6 weeks before kickoff.

Fall: Retreat and DNOW Season

Fall is retreat season, and depending on your ministry, that might mean a traditional fall retreat, a DNOW weekend, or both. We've covered each separately: our fall retreat guide for camp directors and our DNOW shirt guide.

Many DNOW weekends are built around curriculum from publishers like Lifeway or The Gospel Project, so it's worth checking what your group is using before locking in a design direction.

What tends to work best:

  • Super-Soft Tee for the weekend, Super-Soft Hoodie for cooler evenings
  • A single strong theme or verse rather than a schedule-heavy design
  • Woothoop+ for DNOW specifically — tap-to-open schedules, small group signups, and session notes are a natural fit for a weekend that moves fast

Start planning: 6–8 weeks before the event.

Winter: Winter Retreat Season

Winter retreats bring their own set of design and product considerations — colder weather, indoor lodges, and often a more reflective tone than summer camp.

What tends to work best:

  • Super-Soft Hoodie or Super-Soft Crewneck as the anchor piece instead of a short-sleeve tee
  • Puff Ink for raised, textured logos that pair especially well with fleece — it's one of the most popular ink choices for hoodies and crewnecks this time of year
  • Beanies as a practical, on-theme add-on for cold weather

Start planning: 6–8 weeks before the retreat.

Winter: Holiday Events

Christmas services, holiday outreach events, and end-of-year celebrations round out the calendar. These tend to be lower-volume but high-visibility moments — often the biggest attendance Sundays of the year.

What tends to work best:

  • A clean, giftable design — something visitors and first-time guests would be glad to take home
  • Super-Soft Long Sleeve or Super-Soft Crewneck for the colder season
  • A Campfire Mug or Super-Soft Fleece Blanket as a cozy, giftable takeaway for guests and volunteers alike

Start planning: 6–8 weeks before your event, especially with holiday production schedules running tighter across the industry.

Year-Round: Baptisms and Milestone Moments

Unlike the seasonal pushes above, baptism shirts and other milestone merch tend to happen on their own schedule throughout the year. Our baptism shirt guide covers how to design something meaningful for these moments, including how churches are using Water Reveal Ink to visually reflect the moment itself.

Building the Calendar Backward

The single biggest lesson across every season: work backward from your event date, not forward from "whenever we get around to it."

A simple rule of thumb across almost every event type on this list — start the design conversation 4–8 weeks out, depending on how custom your design needs to be. Sunday Cool's 72-hour turnaround after art approval is fast, but that clock only starts once your design is locked and your sizes are in.

If you're ever short on time, a Customizable Design Template is the fastest way to skip the blank-page problem and get to an approved design in days, not weeks.

People Also Ask

What's the busiest season for church merch?
Spring (VBS) and fall (kickoff, retreats, and DNOW) tend to be the two busiest windows, with back to school bridging the two in late summer.

How far in advance should we plan seasonal church merch?
As a general rule, start the design conversation 4–8 weeks before your event, with more lead time for larger or more custom orders.

Do different seasons call for different products?
Yes. Lighter apparel like the Super-Soft Tee tends to fit spring and summer events, while Super-Soft Hoodies, Crewnecks, and Long Sleeves are better suited for fall and winter.

Is there a way to keep our merch cohesive across the whole year?
Sticking to one core color palette or design system — and leaning on bundles like Build Your Brand — helps keep your church's look consistent across every season.

No matter what season you're planning for, the same principle holds: start early, keep the design simple, and choose apparel people will actually want to wear again.

👉 Ready to Get Started?
Start your custom order HERE

Build Your Brand: Cohesive Gear for Ministry Kickoff

Ministry kickoff season is the perfect time to build a cohesive brand. Learn how matching merch bundles create unity across your whole group.

Why Cohesion Matters More at Kickoff

Kickoff is the moment your ministry sets the tone for everything that follows. And tone isn't just what you say from the stage — it's what people are handed on their way in the door.

When your shirt, your sticker, your hat, and your handouts all feel like part of the same visual family, it signals something bigger than "we ordered some swag." It says this ministry is intentional. That's the kind of first impression that sticks with new students, new volunteers, and new families.

This is exactly the thinking behind Sunday Cool's Build Your Brand packages — pre-built merch bundles designed to make cohesive branding simple, instead of something you have to piece together order by order.

Start With a Bundle Built for Kickoff

Rather than ordering a shirt here and a sticker there, Sunday Cool's Build Your Brand line packages coordinated items together — so cohesion is baked in from the start.

A few bundles built specifically with kickoff season in mind:

Take Note Express Package — a Super-Soft Tee, a die-cut sticker, and a Note Jotter Max notebook. Built for back to school and ministry kickoffs, with Sunday Cool's standard 72-hour turnaround.

Decked Out Express Package — the full lineup: Super-Soft Tee, custom hat, Note Jotter Max, and a die-cut sticker. Great for staff branding and kickoff season alike, also on the 72-hour turnaround.

Welcome to the Fam — a Super-Soft Tee paired with a Woothoop wristband and sticker. A simple, budget-friendly way to unify a group fast, especially for welcoming new students or volunteers into the fold.

Each bundle is designed so the pieces feel like they were made together — because they were.

Let One Design Carry Across Every Piece

The easiest way to build a cohesive brand isn't to design five different things. It's to design one strong concept and let it show up everywhere.

Your kickoff theme, color palette, or key phrase should be recognizable whether it's on the shirt, the sticker, or the notebook cover. That consistency is what makes a kickoff feel like a brand moment instead of a merch table.

If you're starting from scratch, Sunday Cool's Customizable Design Templates give you a strong design foundation that can be adapted across every item in your bundle — shirt, sticker, and beyond — without needing five separate design conversations.

Comfort and Quality Still Lead

None of this works if the shirt itself isn't something people want to wear. Every Build Your Brand package is built around the Super-Soft Tee with Super-Soft Ink — the same water-based print process used across Sunday Cool's full apparel line, so the comfort and quality stay consistent no matter which bundle you choose.

Scale Up as Your Brand Grows

Not every ministry needs the same package. Build Your Brand offers options at different speeds and price points:

  • Express Packages (36-piece minimum, 72-hour turnaround) for quick, budget-conscious kickoff pushes
  • Ultimate Packages (125–150-piece minimum, 2–3 week delivery) for a fuller, more elevated brand rollout — including options with Woothoop wristbands, water bottles, or a cinch backpack

Starting small with an Express Package for this season's kickoff and scaling up to an Ultimate Package next year is a completely normal way to build momentum year over year.

People Also Ask

What is the Build Your Brand line?
It's a collection of pre-packaged merch bundles from Sunday Cool that pair a Super-Soft Tee with items like stickers, hats, notebooks, and Woothoop wristbands — designed to create a cohesive look without piecing together separate orders.

Which Build Your Brand package works best for kickoff season?
The Take Note Express Package and Decked Out Express Package are both built specifically with back to school and ministry kickoffs in mind.

What's the minimum order for a Build Your Brand package?
Express Packages require a 36-piece minimum with a 72-hour turnaround. Ultimate Packages require 125–150 pieces with a 2–3 week delivery window.

Can we still customize the design across a whole bundle?
Yes. Every item in a Build Your Brand package can carry your ministry's specific design, whether you start from a Customizable Design Template or work with Sunday Cool's team on something fully original.

Ministry kickoff is the moment your brand gets its first real test. Make it a cohesive one.

👉 Ready to Get Started?
Explore Build Your Brand packages or start your custom order HERE

DNOW Shirt Ideas Your Students Will Actually Love

Planning DNOW shirts for your students? Learn how to design custom Disciple Now weekend shirts that build unity and get worn long after the retreat.

Why DNOW Shirts Are Different

A typical Wednesday night shirt has to work for a whole year. A DNOW shirt only has to capture one weekend — which actually gives you more room to make it specific, bold, and a little unexpected.

Because DNOW compresses so much into 48 hours — small groups, worship, teaching, service projects, chaotic van rides — the shirt becomes a shorthand for the whole experience. Students who went through it together wear it like an inside joke.

That's the bar: not just a shirt with your church name on it, but something that instantly means something to the people who were there.

Design Around the Weekend's Big Idea

The strongest DNOW shirts usually center on one theme, phrase, or verse — the thing students heard over and over across the weekend's sessions.

Resist the urge to cram in the host home groups, the schedule, or every leader's name. A single strong idea, well designed, beats five small details competing for space.

If you want a fast, proven starting point, Sunday Cool's Customizable Design Templates include options built for retreat and weekend-event use — bold typography, Scripture-led layouts, and graphic styles that are easy to adapt to your specific DNOW theme.

For more on why simple, typography-forward designs tend to outperform busier ones, our post on font-based t-shirt design ideas is worth a look.

Comfort for a Weekend That Doesn't Stop

Between host home stays, small group sessions, worship, and service projects, students are in their DNOW shirt for a long stretch with very little downtime.

That's why the Super-Soft Tee paired with Super-Soft Ink is the go-to for weekend events like this. The water-based ink soaks into the fabric instead of sitting on top, so the print stays soft and breathable through a weekend that doesn't slow down.

If your DNOW falls somewhere cold, a Super-Soft Hoodie gives students a warm layer for late-night worship or early Sunday morning wrap-up.

Add a Moment They Won't Forget

DNOW weekends are full of big, emotional moments — a late-night worship set, an unexpected conversation, a group prayer that goes long. Specialty inks are a small way to mirror that energy on the shirt itself.

  • Sun Reveal Ink stays invisible indoors and reveals itself in sunlight — a fun surprise during outdoor service projects or Sunday morning send-off.
  • Puff Ink adds raised, textured detail to a logo or key graphic for a more elevated, tactile finish.

These aren't required, but they're the kind of detail students notice and talk about.

Give Host Homes and Leaders Their Own Look

DNOW runs on host homes and small group leaders, and it's easy to forget them when you're focused on the main student shirt.

A distinct leader or host shirt — same design family, different color — is a small gesture that goes a long way, and it makes leaders easy to spot for students who need help mid-weekend.

Round Out the Weekend

A shirt is the centerpiece, but a few small additions can extend the DNOW experience without adding much to the budget — and one of them can do a lot more than just look good.

Woothoop+ is worth a serious look for DNOW specifically. It's the same soft-woven wristband students already love, but with an NFC chip built in — tap a phone to it, and it instantly opens whatever link you've programmed in. For a weekend built around host homes, small groups, and a schedule that changes by the hour, that's genuinely useful:

  • Program it to open your weekend schedule so students always know where to be next, even when they're bouncing between a host home and the main venue
  • Link it to small group sign-up forms so students can join a group the second it's announced, no digging for a QR code
  • Point it to a digital notes page for the weekend's teaching series, so students can revisit what they heard without needing to remember where they wrote it down

One tap, no app, no lost link. For more on how it works and other ways ministries are using it, check out our posts on how Woothoop+ works and Woothoop+ use cases for ministry.

Beyond that, a couple of other additions round out the weekend nicely:

  • Little Sipper water bottles for a weekend full of service projects and outdoor time
  • Note Jotters for students who prefer pen and paper during small group sessions

Timing Your DNOW Order

DNOW weekends are usually set on the calendar well in advance, but shirt planning tends to get pushed to the back burner behind host home logistics and small group assignments.

A safe timeline: lock in your theme and design 4–6 weeks out, finalize sizes 3–4 weeks out, and place your order with enough runway for Sunday Cool's 72-hour turnaround after art approval to work in your favor, not against a tight deadline.

People Also Ask

What makes a good DNOW shirt design?
The best DNOW shirts center on one strong theme or verse from the weekend rather than trying to include every detail — schedule, host homes, leader names — in one design.

What shirt style works best for a DNOW weekend?
The Super-Soft Tee is the standard choice for its comfort and durability across a packed weekend. A Super-Soft Hoodieis a good add for colder DNOW dates.

Should host home leaders get a different shirt?
Many groups give host home leaders and small group leaders a coordinated but distinct shirt so they're easy to identify throughout the weekend.

Can we use tech-enabled merch like Woothoop+ for a DNOW weekend?
Yes — Woothoop+ is a strong fit for DNOW specifically, since it can be programmed to open your schedule, small group signups, or session notes with a simple phone tap.

How far ahead should we plan DNOW shirts?
Aim to lock in your design 4–6 weeks before the event and finalize sizes 3–4 weeks out, giving Sunday Cool's turnaround time room to work in your favor.

A great DNOW shirt becomes shorthand for the whole weekend — the kind of shirt students keep long after the host homes are cleaned up and everyone's caught up on sleep.

👉 Ready to Get Started?
Start your custom order HERE