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.

Feb 28, 2026
min read

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

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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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VBS Shirt Ideas Inspired by Illumination Station

Discover creative VBS shirt ideas inspired by Illumination Station by Lifeway for VBS 2026. Explore customizable designs and cohesive merch for your theme.

Apr 16, 2026
min read

Designs That Glow With Energy

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Bright, bold, and impossible to miss — like flipping on the lights.

CLICK HERE to use this template

Clean and modern — perfect for leaders and older kids.

CLICK HERE to use this template

Fun, graphic, and full of personality.

CLICK HERE to use this template

Simple and approachable for all ages.

CLICK HERE to use this template

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Minimal, but still exciting and wearable.

CLICK HERE to use this template

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Bring the Theme to Life Beyond the Shirt

CLICK HERE to use this template

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Make It Your Own

Every VBS is a little different.

With Sunday Cool, you can:

  • Start with a Customizable Design Template and adapt it
  • Work with our in-house team to create something original
  • Or upload your approved curriculum artwork, and we'll get it ready for print

Built for Comfort All Week Long

All designs pair perfectly with our Signature Super-Soft Tee, available in youth and adult sizes across most colors.

Soft, lightweight, and easy to wear — so kids actually want to keep it on all day.

Ready to Get Started?

👉 CLICK HERE

These designs are inspired by popular VBS themes and are not affiliated with or endorsed by Lifeway.

Oversized Boxy Tee vs. Signature Tee: What’s the Difference in Fit?

Compare the fit and feel of our Signature Tee and Oversized Boxy Tee with real model examples to find the style that fits you best.

Apr 2, 2026
min read

When it comes to finding the perfect fit, we know one size (or style) definitely does not fit all.

That’s why we’re excited to introduce our Oversized Boxy Tee—a completely different fit from our classic Signature Super-Soft Tee you already know and love.

If you’re wondering “What’s the difference?” or “Which one should I order?”—you’re in the right place.

Let’s break it down 👇

Signature Super-Soft Tee vs. Oversized Boxy Tee: Quick Overview

Signature Super-Soft Tee

  • Classic, everyday fit
  • Slightly tailored through the body
  • True-to-size feel
  • Great for a clean, standard look

Oversized Boxy Tee

  • Relaxed, roomy fit
  • Wider through the chest and sleeves
  • Shorter, boxier silhouette
  • Designed for that laid-back, oversized feel

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Fit Comparison on Real People

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Size Medium Comparison (Model: 5'7")

The difference here is all about shape and drape.

👉 If you like a clean, fitted look: go Signature Super-Soft Tee
👉 If you want relaxed and trendy: go Oversized Boxy Tee

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Size Large Comparison (Model: 6'1")

Size X-Large Comparison (Model: 6'1")

For taller builds, both tees offer great options depending on your style.

👉 Go Signature Super-Soft Tee for a classic fit
👉 Go Oversized Boxy Tee for a looser, more breathable feel

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Size Charts

Signature Super-Soft Tee Size Guide

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S M L XL 2XL 3XL
Width 18" 20" 22" 24" 26" 28"
Length 28" 29" 30" 31" 32" 33"

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Oversized Boxy Tee Size Guide

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S M L XL 2XL 3XL
Width 20 1/2" 22" 23 1/2" 25" 26 1/2" 28"
Length 27 1/4" 28 1/4" 29 1/4" 30 1/4" 31 1/4" 32 1/4"

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Final Thoughts

Both tees are great—it just depends on the look you’re going for.

If your vibe is clean and classic, the Signature Super-Soft Tee is your go-to.
If you're leaning relaxed, bold, and a little oversized, the Oversize Boxy Tee is calling your name.

Ready to Start Your Next Order?

If you are planning shirts for camp, church, or any summer event, this is a solid place to start.

👉 Ready to Get Started?
Start your custom order HERE

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Summer Camp Shirt Ideas Campers Will Actually Love

Explore creative summer camp shirt ideas using customizable templates, specialty inks, and designs your campers will want to wear all year.

Apr 2, 2026
min read

Vintage Camp Badge

There is something timeless about a classic camp badge.

These designs usually include elements like trees, mountains, or camp icons with a structured layout that feels clean and established.

They work especially well for:

  • Traditional summer camps
  • Multi-year programs
  • Camps that want a legacy feel

👉 Featured Template: CA 2506

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Bold Type That Says It All

Sometimes the strongest design is simply a few words done really well.

Big, clean typography with your camp name, theme, or verse creates a look that feels modern and easy to wear anywhere.

This style works best when the message is clear and the layout does the heavy lifting.

👉 Example Design: SR 2044

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Retro Done Right

Retro-inspired designs are having a moment, and they fit camp perfectly.

Think warm tones, vintage fonts, and throwback layouts that feel fun without trying too hard. These are the kinds of shirts students actually keep wearing.

👉 Try This One: SR 2510

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Nature-Inspired Graphics

Camp and nature go hand in hand.

Designs that incorporate sunsets, forests, waves, or mountains help visually tie the shirt back to the experience itself.

This direction works especially well for outdoor-focused camps or locations with a strong setting.

👉 Featured Template: CA 2503

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Scripture-Led Designs

For many churches, the most meaningful shirts are rooted in Scripture.

Whether it is a full verse or a short phrase, these designs carry the message of camp beyond the week itself. The key is keeping it readable and wearable.

👉 Example Design: SR 2506

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Clean and Minimal

Not every camp shirt needs to be loud.

Some of the most worn designs are the simplest ones. Subtle graphics, clean layouts, and intentional spacing often lead to shirts that feel more versatile.

👉 Try This One: FA 2408

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Specialty Ink That Changes Everything

If you want something campers talk about all week, this is it.

With our Sun Reveal Ink and our Water Reveal Ink, your design becomes interactive:

  • Sun Reveal Ink reacts in sunlight
  • Water Reveal Ink activates when wet

These are perfect for outdoor games, pool time, water days, and even baptism celebrations during camp.

It turns your shirt into part of the experience, not just something you wear.

👉 Featured Template: WR 2201 and SUR 2302

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Designs Built Around Your Theme

Every camp has a theme. The best shirts bring that theme to life without overcomplicating it.

Whether it is something bold or something simple, a strong layout paired with the right words creates a shirt that feels intentional and memorable.

👉 Example Design: SR 2315

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Start With a Template (and Make It Yours)

The easiest way to get started is not from a blank page.

With our Customizable Design Templates, your team can:

  • Choose a design that fits your camp
  • Customize text, colors, and details
  • Work with our in-house artists if needed
  • Approve and move forward quickly

It is all built to take pressure off your team while still giving you something that feels thoughtful and well-designed.

Ready to Create Your Summer Camp Shirts?

The best camp shirts are the ones campers keep wearing.

When the design is strong, the message is clear, and the shirt feels great, it becomes more than just merch. It becomes part of the memory.

👉 Ready to Get Started?
Start your custom order HERE

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People Also Ask

What makes a good summer camp shirt?

The best camp shirts combine a clear design, comfortable fabric, and a style campers actually want to wear beyond the week.

Should we design camp shirts from scratch?

Not necessarily. Many churches start with Customizable Design Templates and personalize them to save time while still getting a strong design.

What are popular summer camp shirt styles?

Vintage badges, bold typography, retro designs, and nature-inspired graphics are some of the most popular styles right now.

Can camp shirts be interactive?

Yes. Specialty inks like Sun Reveal Ink and Water Reveal Ink create interactive designs that respond to sunlight or water.

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