Running a print on demand business can feel like a dream: no inventory, no upfront stock, and minimal logistics.
But there’s a catch. You’re putting your brand’s reputation into the hands of someone else to print and ship the product. And that means quality control becomes your biggest risk and responsibility.
If you want to avoid refund requests, bad reviews, and customer churn, then quality control can’t be an afterthought.
In this guide, I’ll walk you through every method I’ve used to keep product quality high, even when I never see the inventory myself.
Whether you’re selling through Shopify, Etsy, or any other ecommerce platform, these tips will help you protect your business and build trust with customers.
Order Samples Regularly
One of the most effective ways to ensure quality is to order your own samples. This is something I do every time I release a new design or add a new product to my store.
Why Sampling Matters
Ordering a sample is the only way to know exactly what the customer will receive. Mockups are helpful, but they don’t reflect the real-life texture, print placement, or packaging. By ordering a sample, I can:
- See the actual print quality and color accuracy
- Check for misalignment or poor placement
- Test the garment’s softness and fit
- Verify the packaging and branding elements
- Experience the actual shipping time
Frequency of Sampling
I’ve found it’s not enough to order a sample once. Over time, print providers might switch garment brands or change printers.
Fulfillment centers may relocate your orders to a different region. To maintain consistency, I recommend this sampling schedule:
| Sample Frequency | When to Order |
|---|---|
| New Product | Always before launch |
| Every 3 Months | Ongoing quality check |
| After Complaints | When a customer reports issues |
| Supplier Change | If your provider updates fulfillment locations |
Sampling is an investment, but it saves you from unexpected customer issues later.
Use High-Resolution Print Files
If your designs are blurry or pixelated, there’s no fix once it hits production. That’s why I always make sure my files meet industry standards.
Print File Specs That Work
To keep things sharp and professional, I use:
- 300 DPI minimum
- Transparent PNG files (especially for apparel)
- CMYK color mode if the provider requires it
- Dimensions that match the print area exactly
I never stretch a low-resolution image to fit. It always ends up looking unprofessional. Instead, I scale designs properly in Photoshop or Illustrator to avoid compression artifacts.
Design Placement Tips
Another aspect of print quality is placement. Off-center designs or prints too close to the neckline look amateur. When uploading designs to platforms like Printful or Printify, I always:
- Use center guides or placement templates
- Leave a safe margin (at least 1 inch from edges)
- Check how it looks on every size (XS through 3XL)
Even if the file is technically perfect, poor placement can ruin the final product.
Choose the Right Print Provider for Each Product Type
Not all print on demand providers are equal. Some specialize in specific products, and trying to force them into other categories usually leads to poor results.
What I Look For in a Provider
When selecting a supplier, I prioritize:
- Product variety
- Printing technology (DTG, sublimation, embroidery)
- Reviews and ratings from other sellers
- Print quality consistency
- Location of fulfillment centers
- Shipping speed and cost
Based on this, I’ve built a short list of providers I use for different types of products:
| Product Type | Preferred Provider |
|---|---|
| T-Shirts | Printful or Awkward Styles |
| Hoodies | Printify (Monster Digital) |
| Wall Art | Gooten or Gelato |
| Mugs | Printify (District Photo) |
| Jewelry | ShineOn |
| Phone Cases | CaseApp or Gelato |
Avoiding a One-Size-Fits-All Approach
It’s tempting to stick with just one provider for everything. But if you’re serious about quality, it makes sense to diversify.
For example, I use Printful for apparel but rely on Gooten for framed prints because their quality is better for that niche.
Read Reviews About Your Fulfillment Partners
Before trusting a provider, I always read what real users are saying. Trustpilot, Reddit, Facebook groups, and Etsy forums are gold mines for honest feedback.
Where I Check for Red Flags
Some sources I rely on include:
- Trustpilot: Look for consistent patterns in complaints
- Reddit (r/printondemand): Candid reviews and screenshots
- Etsy seller forums: Insight into fulfillment issues
- Product reviews on third-party stores using the same provider
This research tells me what to expect and helps me catch potential problems early. For example, I once avoided using a popular provider because their mugs had repeated complaints about fading after one wash.
That saved me dozens of returns.
How I Track Ongoing Performance
Even after choosing a provider, I continue checking recent reviews at least once a quarter. If I see a drop in ratings, it’s usually a signal that something has changed—new materials, different printers, or delayed shipping.
Collect Customer Feedback Post-Purchase
Your customers are your best quality control team. They see what you don’t, and if you give them a way to share honest feedback, you can catch issues before they become widespread.
How I Gather Feedback
I use email follow-ups and review apps to ask specific questions:
- Was the print aligned correctly?
- How did the material feel?
- Was the item true to size?
- Would you upload a photo of your purchase?
I use tools like Judge.me or Loox to automate this, and I also review photo uploads carefully. If a customer posts a shirt with crooked text or a faded image, I follow up with them and investigate with the print provider.
Using Feedback to Improve
If I notice recurring feedback, I take action. For example:
- If customers complain about sizing, I update the product description
- If print quality is inconsistent, I switch providers
- If mockups don’t match the final product, I replace them
This has helped me maintain a strong review average across platforms.
Use Accurate and Honest Mockups
Mockups can either build trust or backfire. If the mockup looks polished but the final product doesn’t match, your customers will feel misled.
What I Avoid in Mockups
There are plenty of mockup generators that show 3D or lifestyle images, but I avoid overly stylized or unrealistic ones. Instead, I focus on:
- Flat lay images that show true print size
- Mockups with minimal lighting adjustments
- Side-by-side mockup and sample photos
- Including sizing charts next to the image
This gives buyers a real sense of what they’ll receive and prevents disappointment.
Custom Mockups vs Platform Mockups
Most platforms provide mockup generators, but they often use generic models or inaccurate colors.
I’ve found better results by creating my own mockups using high-resolution templates from sites like Placeit or SmartMockups. This gives me control over background, shirt color, and scale.
Monitor Return Rates and Complaints
Returns are an inevitable part of ecommerce, but I treat every return as a potential quality issue. If my return rate spikes above 2 to 3 percent, I start digging.
How I Track Return Reasons
I use Shopify’s return management system or third-party tools like AfterShip or Loop Returns. I label every return by reason, such as:
- Wrong size
- Print issue
- Damaged on arrival
- Not as described
By tagging and tracking this data, I can create monthly reports to find patterns.
| Return Reason | % of Total Returns |
|---|---|
| Print Misalignment | 27% |
| Wrong Size | 22% |
| Faded Print | 18% |
| Shipping Damage | 14% |
| Other | 19% |
This helps me make data-driven decisions. If print misalignment is trending up, I know it’s time to investigate the fulfillment center or re-upload my print files.
Upgrade to Better Garment Blanks
When I first started, I used the cheapest options available, like Gildan 5000 shirts. They were cost-effective but resulted in higher complaints about feel, fit, and shrinkage. Now I’ve switched to better-quality blanks.
My Favorite Upgrades
Here are a few I use and recommend:
- Bella+Canvas 3001: Soft and lightweight, great fit, costs around $9 on Printful
- Next Level 3600: Slightly more fitted, smooth print surface, about $8.50
- Stanley/Stella (EU): Eco-friendly, premium quality, $10 to $12 per piece
While these cost a few dollars more, they cut down on returns, increase repeat purchases, and justify higher pricing.
Why Quality Blanks Matter
Cheap shirts often feel stiff, shrink in the wash, or lose shape quickly. That reflects directly on your brand. By upgrading, I can position my store as more premium and charge $30+ per tee without complaints.
Set Clear Expectations on Quality and Shipping
Managing expectations is just as important as managing quality. If a customer expects Amazon Prime speed and gets a 7-day production window, they’ll be unhappy no matter how great the product is.
What I Communicate on My Store
To reduce complaints and increase trust, I clearly explain:
- Production times (usually 2 to 5 business days)
- Shipping times by country
- The handmade nature of the product
- Slight variations in print alignment or color
I include this info on product pages, confirmation emails, and my FAQ page.
Framing Quality as a Feature
I also talk about how each item is made to order. This gives me a way to reframe any small imperfections or delays as part of the uniqueness of the product. Instead of making excuses, I highlight the craftsmanship.
Always Have a Backup Supplier
No matter how reliable your supplier seems, issues can happen. Printers break. Stock runs out. Locations shut down. That’s why I keep backups for every key product in my store.
How I Set Up Redundancy
If I sell a best-selling hoodie through Printify, I also create the same listing using Printful, even if it’s unpublished. That way, if something goes wrong, I can switch the product over quickly.
I store my design files, print specs, and mockups in Google Drive, organized by product and supplier. This makes it easy to relaunch products with another provider if needed.
Final Thoughts
Print on demand gives you freedom, but with that comes responsibility. You can’t afford to be passive about quality control.
Every touchpoint, from the design file to the sample to the mockup to the final package, impacts how your customer sees your brand.
By applying these quality control tips consistently, I’ve been able to scale my POD store, reduce refund rates, and keep customers happy. It takes extra time upfront, but the payoff is long-term trust and fewer headaches.
