The Sunday Cool Screen Printing Process: Start to Finish

When it comes to printing water-based inks on Comfort Colors® garments, knowing how your artwork will appear on different dye types is key to getting the look you want. Comfort Colors’ pigment and reactive dye processes affect how much ink discharges through the garment dye - meaning your design’s final vibrancy can vary from bold and bright to soft and vintage.

In this guide, we’ll break down the four main categories of print results: Reactive Dyed, 90% Vibrancy, 70% Vibrancy, and 40% Vibrancy.

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Reactive Dyed Garments - Vibrant Prints

Reactive dyed garments deliver the most vibrant print results. These shirt colors release more dye when printed, allowing the water-based ink to fully discharge and produce bright, bold colors that pop right off the fabric.

Other Reactive Dyed Colors include: Red, Midnight, White, and China Blue

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Pigment Dyed - 90% Vibrancy

Pigment dyed garments naturally have a soft, washed-in look, and they’ll continue to fade slightly over time for that perfect “lived-in” feel. Colors in this range print at about 90% vibrancy, meaning they still hold strong color but with a subtle vintage look.

Other 90% Pigment Dyed Colors include: Citrus

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Pigment Dyed - 70% Vibrancy

These garments bring a classic vintage feel - the kind of tee that looks like it’s been your favorite for years. Prints appear softer, more muted, and intentionally weathered.

Other 70% Pigment Dyed Colors include: Neon Cantalope, Neon Lime, Bay, Mustard, Melon, Orchid, Hydrangea, Celadon, Bright Orange, Burnt Orange, Royal Caribe, Sapphire, Bright Salmon, Crunchberry, Watermelon, Seafoam, and Ice Blue

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Pigment Dyed - 40% Vibrancy

This category represents the most vintage of pigment dyed results. The garment color holds onto more of its original pigment, giving your print a subtle, tonal appearance. Think soft, muted designs that look like they’ve been sun-washed over time.

Other 40% Pigment Dyed Colors include: Periwinkle, Grass, Boysenberry, Violet, Blue Jean, Flo Blue, Yam, Neon Pink, Cumin, Crimson, Blue Spruce, and Hemp

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Side-by-Side: Graphite (Reactive Dyed) vs Pepper (Pigment Dyed)

Here’s where the difference really shows. Both Graphite and Pepper are dark gray Comfort Colors tees - but their dye processes create dramatically different print results.

• Graphite (Reactive Dyed): Produces bright, and high-contrast prints with truer color accuracy.
• Pepper (Pigment Dyed): Prints appear muted and washed-in, creating a naturally vintage look right out of the box.

This comparison is the perfect example of why knowing your garment’s dye type matters when planning your artwork as the base color and dye process can completely transform the final result.

Bringing It All Together

Understanding how your garment’s dye impacts print results helps you choose the perfect combo for your design. Whether you’re aiming for bold and bright or soft and nostalgic, our team will help ensure your Comfort Colors order prints how you envision it.

Water based ink is the point between here and heaven. Paired with our Super Soft Tees, the nonexistent feel of our Water based ink is magical and sure to be the talk of the town with you and your group.

Here at Sunday Cool, we inventory 66 different ink colors! These colors were curated based off of customer popularity and diversity. You can view those stock ink colors below.

During the ordering process, you can reference this page to view all of our stocked ink colors. You’ll also be served up a choice of our stock inks when you submit your Art Request Form.

But what if none of the Sunday Cool Stock Inks match my design or logo? Nothing to fear! We can Pantone Match your ink to whatever code you’re needing to a 90% accuracy. 

There are a few requirements to qualify for a Pantone Match on your project:

• Stick to our Super Soft Signature line of apparel.
• The garment color you choose must discharge vibrantly, not vintage. If you need help determining which of our inventory items discharge at which rates, check out our blog post entitled Waterbased Print Results.
• Your order must include 144 units or more. 

Additionally, we charge $25/match! This means if we need to match 2 ink colors to a specific code, it’ll be a $50 charge.

But how do I know which code to send you? Great question! Your organization might have a branding guide including all relevant codes and colors that set your group apart. OR you could send in your logo and ask us! Our talented Art Staff can color match the logo and tell you the code! We work often in the Pantone and HEX libraries!

As always, if you have any questions regarding our inks & matching guides, please reach out to a Sunday Cool Concierge member using the dot icon in the corner of your screen.

‍Everything you need to know before placing an order

Custom foam trucker hats are one of the most versatile, affordable, and memorable pieces of group apparel out there. Whether you're gearing up for summer camp, planning a conference giveaway, or refreshing your church's merch table, a well-designed hat can tie everything together — without breaking your budget.

But before you hit "Get A Quote," let’s break down what makes a great custom foam trucker hat, what to look for in a print partner, and why these foam-front classics are trending hard right now.

Why Choose Foam Trucker Hats?

Custom hats are everywhere. But foam trucker hats? They're in a league of their own — and for good reason.

• They’re lightweight and breathable, making them ideal for hot climates, long events, and high-energy environments like summer camps or youth group retreats.
• They have high visibility — literally and figuratively. A bold print on a foam front panel makes your design stand out in photos, on stage, or across the rec field.
• They’re cost-effective. Compared to embroidery-heavy or premium headwear, foam truckers are easier on your budget.
• They’re just plain fun. Custom foam trucker hats instantly add personality to your group, team, or brand.

What to Consider Before Ordering Custom Foam Trucker Hats

Before submitting your design, here are a few things to think through to make sure your order checks all the right boxes:

1. What’s the goal?

Are you ordering hats for a staff team? Volunteers? Conference giveaways? A mission trip?
Foam trucker hats work great for events where you want something eye-catching, useful, and easy to pack or distribute.

2. How many do you need?

Whether you're ordering a dozen for your youth leaders or a few hundred for an event, our 72-hour turnaround makes it easy to get what you need, fast. Foam truckers are especially great for bulk orders.

3. Do you already have a design?

Our most popular option is to print directly onto the foam front using full-color Digital Ink. That means more flexibility for your design and more vibrancy in the final product. Embroidery and custom patches are available to order as well.

Not sure what to print? Our team of world class artists can help turn your theme or logo into a high-impact hat graphic.

4. What’s your timeline and budget?

At Sunday Cool, our foam trucker hats ship out within 72 hours after artwork approval. No rush fees. No guesswork. Just a lickity-split turnaround.

How Sunday Cool Does Foam Trucker Hats Differently

Not all custom hats are created equal. Here's why Sunday Cool's foam trucker hats are trusted by hundreds of camps and churches.

• Full-color printing with Digital Ink — your design prints crisp & vibrant.
• Low minimums — order a few, or a few hundred*
• Soft foam front with mesh backing — comfortable, breathable, and made to wear again
• Printed in-house by real humans — not robots or drop shippers!!

We’ve printed thousands of these for churches, ministries, and events that wanted something a little more fun, a little more memorable, and a lot more wearable.

*orders start as low as 12 pcs

FAQs About Custom Foam Trucker Hats

How much do foam trucker hats cost?
Pricing depends on your quantity, but foam truckers are one of our most budget-friendly high-value promo options. Click HERE to Get a Quote today.

What kind of file do I need to upload?
A high-resolution PNG or AI file works best. But if you’re not sure, our team will check your artwork and make it print-ready.

Can I see a proof before printing?
Always. We’ll send you a digital mock-up to review and approve before anything goes to print.

What if I don’t have a design?
No problem. Just give us a theme, idea, or logo and we’ll help you create something that looks great on a foam front.

Ready to Design Your Custom Foam Trucker Hats?

When you're working with tight timelines, limited budgets, and high expectations — you need a hat partner who gets it.

At Sunday Cool, we combine fast turnaround, remarkable customer service, and those signature specialty ink prints to bring your ideas to life — on t-shirts and trucker hats alike.

Start Your Hat Order Today