WHAT'S THE COST OF DOING NOTHING? EXPLOITING THE GROWTH OF ON DEMAND GARMENT PRODUCTION
How a long-established family business and a digital native chose to get busy?
The direct to garment industry has gone from strength to strength over the last 10 years. As a disruptive technology offering a digital alternative to manual or semi-automatic screen printing - Digital DTG has quickly become the industry’s fastest growing sector - and with good reason!
The global market for custom t-shirt printing alone is expected to cross $10 billion US Dollars by 2025 at a CAGR of 6.3% through the forecast period 2017-2025. (Source: Credence Research). Digital technology unlocks a dynamic world of opportunity - its fast, affordable and versatile - and importantly meets the needs of a new consumer with an acute requirement for on-demand manufacturing at any scale. The requirement for infinite iterations and multiple personalised products within the sector is spawning many new successful and highly profitable B2B and B2C business models.
How has the sector changed - what does the future hold?
Digital technologies have advanced over the years to offer a seamless, efficient and highly profitable garment decoration industry. As print volumes have grown the average cost of production has fallen to create many new opportunities. Delivering; high print quality, exceptional colour, superb fabric handle, high speed production, workflow automation and operational efficiency. As a sector utilising disruptive technology entrepreneurial growth is high with many new entrants to the print marketplace.
Based in Cheshire Shirt Monkey and its founder Nic Simons demonstrate an entrepreneurial DTG success story.
With no previous experience in textile printing Nic Simons set up his company from home in 2013. Whilst unsuccessfully trying to source print for his own business he soon saw the future potential of digital garment production at scale and began his digital journey using Brother technology. Nic has since built a vibrant print on demand production facility offering a B2B print service and provides online 3rd party ecommerce fulfilment.
The business produces over 550,000 individual garments per year, sold predominantly in the UK to a network of loyal clients and online brands. The business model is built to offer 3rd party online fulfilment, on demand. Shirt Monkey have encouraged their loyal clients to shift to online fulfilment where possible. They aim for next day delivery, however, supply chain issues and double-digit growth during the pandemic have put an operational strain on the business. Re-equipping with a further two Kornit machines to meet a surge in sales has now been achieved. Scaling at pace does create challenges - hence the move to new premises and further investment in Custom Gateway to expediate the production workflow from the moment of sale to dispatch.
“Growth has been swift and our print suite here at Shirt Monkey now operates with 6 Kornit Avalanche HD6 DTG machines. We are currently in the process of moving to a new 25,000 sq.ft premises and expect to expand print capacity further in the future with room for another 6 Avalanches, bringing the total to 12 high speed, high quality pigment based print machines” - Nic Simons - Shirt Monkey
“Our business supports an infrastructure of reactive manufacturing, its risk averse and our clients hold either a small stock or no stock. Orders are driven by purchase activated manufacturing or intelligent sales data driven by predictive merchandising trends. We offer a simple pricing structure and have created an equally simple automated sales strategy online”.
“As ecommerce technologies have developed our customers have thrived, as has our commercial vision - online is booming. Intuitive ecommerce platforms such as Shopify have accelerated the growth of e-retailing and generated an explosion in designer brands. Augmented reality, and visual simulation technologies go further to build growth as the consumer becomes increasingly confident to create and purchase in the cloud”.
“We have built our reputation on high quality, exceptional customer service and speed of delivery. Growth has been organic to date, and our business has grown alongside its reputation. As we move forward with our expansion plans, we will invest further in marketing to support growth. For the future I can see us having a production hub located in Europe and in 2021 we will seek external finance to expand the business”. Nic Simons – Founder, Shirt Monkey.
Established screen printers are investing in digital technologies to provide hybrid production for personalised printed products
Based in North Wales Jami Q’s are a family business that has been trading for over 20 years.
Built on a bedrock of screen-printed products and an impressive catalogue of many hundreds of customisable products, the company are tooling up for the future and have invested over the last 5 years to build a suite of Kornit Digital DTG printing machines. Currently production is 80% screen and 20% digital, printing over 1,500 products per day in a hybrid production workflow. Clients increasing require super-fast delivery with optimum agility – order sizes vary, as does product complexity and production can be programmed for maximum efficiency.
Tomos Kneale of Jami Q’s is very proud of his family achievements and believes adapting to market trends is essential for future success –
“Digital technologies are getting close to competing with screen print, we are approaching a tipping point. Demand has grown for customisation, and in our business orders for personalised products are equally strong. Costs for small orders using digital technologies are vastly reduced, the quality of DTG print technology has improved dramatically and the gap between digital and screen is decreasing” Tomos Kneale - JAMI Q’s.
“In my view digital will become the technology of choice and screen print will be utilised for artisan production and specialist applications very soon”.
“Our business has an USP and a reputation for superfast, efficient service. To achieve this, we operate on a strict production protocol and a transparent production workflow. We offer exceptional customer service and value to our clients. We are investing in our ecommerce platforms to further enhance our customers experience and simplify the customised ordering process. Our ongoing investment in DTG technologies will further support our objectives”.
“Looking forward we are excited by the prospect of simplifying our polyester printing process to utilise digital, this will also extend our personalised product offering utilising our existing catalogue. High visibility garments offer us a new opportunity for expansion as do printed polyester garments and an accelerating requirement for fashionable workwear with style, we aim to offer a range of durable garments that can also be worn outside the office”.
“Sustainability is also high on our agenda, and the Kornit NeoPigment inks offer a certified, eco-friendly platform for our printed products. Kornit Digital is well placed for sustainable production and supports our vision to offer inherent sustainability at the heart of production and our own label brands.” Tomos Kneale – Jami Q’s
It’s more than just T-shirts - DTG Technology has expanded and evolved far beyond its original purpose to unlock new marketplaces and new product applications
Fashion, Sportswear, Workwear, Childrenswear, Athleisure garments, Accessories and promotional items offer an array of new markets for expansion and commercial development.
Summary of Key factors driving demand:
Customisation is big business and it’s driving accelerated growth.
Creativity - Design and product diversity are in high demand.
New technologies - Offer expanded applications and generate new markets.
Entrepreneurial business models - Flourish and continue to democratise the sector.
Print on Demand - Agile manufacturing is risk averse, it removes dead stock and lost profits.
Speed of Production - Instant manufacture is a modern-day requirement regardless of volume.
Ecommerce and workflow automation now offer seamless production efficiency. As the market for customised, personalised products accelerates a suite of automation technologies have developed in tandem to create the perfect storm. Controlling multiple orders - each with unique attributes - demands automation, without which production slows and operational costs and errors increase.
The consumer demands product diversity at speed - implementing workflow automation delivers transparency upstream and down to support the DTG manufacturing cycle and to successfully navigate the product and its embedded specifications from the point of sale through manufacture and onto dispatch.
We are still only at the beginning of the direct to garment decoration phenomena. Future growth will accelerate in line with the exponential rise of ecommerce and the demand for customisation in a sustainable manufacturing ethos.
We thank Jami Q’s and Shirt Monkey for their support in researching this article and wish them both every success and a prosperous digital future. To be continued....
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Is the Textile Market Finally Recovering?
After a difficult few years, there are genuine reasons for optimism. Duncan was candid about the challenges: "The market for textiles has been very difficult over the last three years. I'm not going to hide the truth there. But the tide is turning.“
A profound shift is currently reshaping the sector
Changing consumer expectations demand greater design diversity, faster turnaround times, and sustainable manufacturing practices.
To thrive, interior brands must adapt their supply chains, bringing production closer to the end consumer and moving away from bulk manufacturing.
Digital textile printing offers a definitive solution to these operational bottlenecks.
Digital transformation doesn't announce itself.
It accumulates - one innovation at a time - until an entire industry looks back and realises the ground has shifted beneath its feet. That's precisely where textiles stands today.
The conversations happening now about AI, automation, sustainability, and digital product passports are not theoretical. They are shaping decisions being made on factory floors and in boardrooms right now.
“By leveraging advanced digital textile printing, Marylene Madou has successfully merged traditional craftsmanship with cutting-edge technology. Her approach offers a blueprint for how independent designers can scale their brands globally while maintaining a minimal environmental footprint.”
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But what makes Marimekko's story compelling is not just its aesthetic legacy?
The textile industry is undergoing a vital transformation. As the insights from Techtextil and Texprocess reveal, the path forward relies on a combination of sustainable hardware, intelligent chemistry, and seamless digital workflows.
From Zimmer's industrial-scale energy reductions and Stratasys's on-demand 3D embellishments, to Kornit's single-step technical printing and the unified digital ecosystems of NedGraphics and Optitex, the tools for change are here. To stay competitive, brands and manufacturers must adopt these innovations, moving away from fragmented, wasteful processes towards a truly connected, circular economy.
Friedmans stands as a testament to the power of combining traditional textile knowledge with forward-thinking innovation.
“Operating from their UK headquarters, Friedmans now serves a diverse array of sectors, including swimwear, dance, entertainment, sportswear, interior decor, prosthetics, and even pet apparel. With a strategic supply chain that reliably serves clients worldwide”
The apparel decoration industry is decisively moving away from isolated, analogue production tools toward connected digital manufacturing environments.
"Kornit’s unwavering commitment to transformative technology continues to disrupt the status quo. For business leaders and innovators ready to capture the future of apparel manufacturing, the path forward is clear”
The Urgent Need for Sustainability at Scale
The transformation at Coats provides a vital blueprint for the wider textile and apparel sector. True sustainability cannot be achieved in silos. As Dearing emphasised:
“Cross-industry collaboration is the engine of meaningful change. Brands, machinery suppliers, chemical providers, and fibre producers must act as an interconnected ecosystem”
Today’s customers demand superior product quality, real-time data visibility, and lightning-fast turnaround times.
For large-scale garment decorators, managing these expectations while balancing seasonal demand fluctuations - such as the massive surges seen during Black Friday - presents a monumental challenge.
"Relying on transactional vendor relationships and outdated legacy equipment is no longer sufficient to secure long-term stability and growth.”
Printing method is never a secondary detail. It shapes the entire life cycle of a product, from concept to customer. In today’s fashion industry, where margins are tighter and speed matters more than ever, technical knowledge has become a competitive advantage.
“The future of textile design belongs to professionals who can combine creativity with execution, aesthetics with practicality, and vision with production reality”.
Are we witnessing the reinvention of Merch driven by adaptive, digital technologies?
The commercial opportunity presented by printed, personalised merchandise is already a lucrative revenue stream; it is the core driver of growth in a multi-billion-pound industry. And the mandate for print businesses is clear: automate, adapt, and offer undeniable added value, or choose to gradually lose market share.
Powderless DTF is an important area of innovation. It deserves research, investment, and thoughtful development.
“But at its current stage, it often feels like the industry is attempting to commercialize the concept ahead of the underlying chemistry and system readiness”.
All Apparel Manufacturers face an Urgent Mandate: “Automate or be Left Behind”.
Industry leaders like Super Nova Sports and Ryozo International were struggling with severe pre-press bottlenecks and unsustainable fabric waste. By integrating AI Sublimation Software into their workflows, these forward-thinking businesses eliminated manual variable data entry, boosted fabric efficiency to over 80%, and reduced delivery times by more than half, establishing a highly profitable, agile, and environmentally responsible production model.
The Future of Manufacturing belongs to those who Embrace Connected Digital Ecosystems
“Whether you produce garments, car interiors, or home furnishings, the transition from creative concept to production-ready product often remains fragmented. Design teams work tirelessly to develop compelling materials, yet technical teams struggle to interpret these visions without losing data along the way.”
The European digital wallcovering marketplace is expanding at an impressive rate.
“For print professionals and interior designers, this transition presents a distinct set of challenges. Achieving flawless colour consistency, managing complex substrates, and meeting stringent environmental standards are no longer optional extras; they are fundamental requirements for commercial success.”
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A swimsuit might start life as a sketch. By the time it reaches the shop floor, dozens of hands have touched it - designers, dye houses, printers, trim manufacturers, quality controllers. Each one interprets colour in their own way, under their own conditions, with their own tools. The result is often a product that looks nothing like the original vision.
Dorking – UK – August 2026 – The FESPA Awards 2027 are set to open for entries, inviting print and signage professionals from around the world to showcase their finest work on the industry's most prestigious global stage.
With an early bird deadline of 31 August 2026 and a final entry deadline of 2 December 2026, the call is clear: the time to prepare is now
London – UK – August 2026 – Vivid Technologies has announced that its flagship product, Razar, has been shortlisted in the Manufacturing category of the prestigious Stationers' Innovation Excellence Awards 2026.
The nomination recognises Razar as a standout example of forward-thinking innovation within the manufacturing sector.
Clay Cross – August 2026 – Resolute DTF has announced it will take a prominent stand at The Print Show 2026, held at the NEC Birmingham from Tuesday, 29 September 2026.
The company will also maintain a presence at The Sign Show, which is co-locating with the event, marking a significant dual appearance for the brand at one of the UK's most anticipated print industry exhibitions
Regensburg, Germany – August 2026 – OneVision has announced the release of software version 26.2, marking a significant step forward in intelligent print automation.
The update introduces new artificial intelligence capabilities, expanded Variable Data Printing (VDP) functionality, and enhanced production monitoring tools designed to help print service providers increase efficiency and output quality.
Version 26.2 introduces a suite of AI Services that seamlessly integrate GPU-accelerated artificial intelligence into existing print production workflows.
SOUTH NORMANTON, UK – August 2026 – Sun Chemical has announced that its Xennia Sapphire pigment inks for digital textile printing have received three of the industry's most sought-after regulatory certifications: GOTS (Global Organic Textile Standard), ECO-PASSPORT, and ZDHC (Zero Discharge of Hazardous Chemicals).
The achievement positions Sun Chemical as a frontrunner in sustainable and compliant digital textile printing solutions.
London UK – July – 2026 – British digital fabric printing company Prinfab has been commissioned to produce a commemorative tea towel to celebrate the landmark birthday of iconic English fashion designer Sir Paul Smith.
The bespoke piece features hand-drawn self-portraits of nearly 800 members of his team, making it a truly unique tribute to one of Britain's most celebrated designers.
The tea towel, gifted to Sir Paul Smith by his team, showcases the creative spirit that has long defined the Paul Smith brand.
Manchester – August 2026 – Premier Digital Textiles today highlights its 2555 Dimout, a versatile, dual-purpose fabric designed to bridge the worlds of fashion and interior design.
With its distinctive silver finish and subtle sheen, the fabric is positioned as a premium material for designers and makers operating across both industries.
2555 Dimout features a smooth silver surface that lends itself naturally to elegant occasionwear, flowing garments, and bold statement pieces.
Its fluid drape and refined aesthetic make it particularly well-suited to summer collections, where lightness and visual impact are equally valued.
Oswestry – Shropshire – August 2026 - Fujifilm Ink, the UK-based global supplier of UV inkjet technology, has strengthened its partnership with China Print Supplies UK Ltd (CPS), becoming the recognised ink supplier for the company's range of Dlican UV printing systems.
The partnership follows the successful rollout of Fujifilm Ink's thermoforming flexible ink technology, reinforcing the company's commitment to delivering high-performance, application-specific ink solutions for the wide-format print market.
Birmingham, UK – July 2026 – swissQprint UK is set to exhibit at The Print Show 2026, taking place from 29 September to 1 October at the NEC in Birmingham, Great Britain.
Visitors can find the swissQprint UK team at Stand P420, where they will have the opportunity to experience the company's latest flatbed printing technology firsthand.
Paris, France – August 2026 – Optitex and NedGraphics will present their integrated design and manufacturing solutions at Première Vision Paris, taking place from 1st to 3rd September 2026 at Parc des Expositions, Paris Nord Villepinte, France.
Visitors can find the companies at Booth 3L11 in Hall 3, Smart Creation Area.
The joint appearance marks a significant opportunity for textile brands and manufacturers to experience first-hand how NedGraphics and Optitex deliver a unified workflow — one that connects textile design, colour refinement, and end product development within a single, seamless process.
Emmerich am Rhein, Nordrhein-Westfalen – August 2026 – Brother Industrial EMEA has announced the launch of its GTX300, a hybrid direct-to-garment (DTG) and direct-to-film (DTF) garment printer that the company says sets a new benchmark for textile print quality.
To mark the occasion, Brother Industrial EMEA is offering eligible print professionals across the EMEA region a complimentary demo package to experience the printer's capabilities firsthand.
FREMONT, CA. August , 2026 – Fiery, a global leader in digital printing technology, has announced the launch of a new free online course designed to help print professionals master colour management for direct-to-film (DTF), direct-to-garment (DTG), and UV printing workflows.
The course, Fiery Specialty Production 301 v1: Colour Management Basics in Digital Factory, is now available on Fiery's learning platform at no cost.
Geretsried, Bavaria, August 2026 – RUDOLF, a leading textile chemistry company, has announced the launch of its Summer Campaign, a dedicated series exploring advanced finishing technologies designed to enhance the performance, comfort, and protection of swimwear and summer apparel.
The campaign arrives at a time when the demands placed on modern swimwear are greater than ever. Prolonged sun exposure, repeated contact with water, and the physical demands of summer activities require textiles that go beyond attractive design.
RUDOLF's Summer Campaign aims to demonstrate how the right finishing technologies can meet these challenges head-on.
Frankfurt, Germany – August 2026 – Heimtextil, the world's leading trade fair for home and contract textiles, has announced the launch of the Italian Lounge, a dedicated exhibition space celebrating Italian craftsmanship at its 2027 edition.
Taking place from 12 to 15 January in Frankfurt, the Italian Lounge will be located in the heart of Hall 4.1 and will bring together manufacturers of decorative and furniture fabrics, leather, and fibres and yarns under one roof
Pembrokeshire, Wales – August 2026 – National Weaving, a family-owned textile manufacturer with nearly four decades of experience, was honoured to receive a visit from HRH The Princess Royal, President of the UK Fashion & Textile Association (UKFT), at its Pembrokeshire facility.
The visit celebrated the company's longstanding contribution to British textile manufacturing and its commitment to combining traditional craftsmanship with modern, sustainable production methods.
PHILADELPHIA – July 2026 – PRINTING United Alliance, in partnership with The Foundation for Graphic Communication Education (The FGCE), continues to expand its popular Student Day experience at PRINTING United Expo 2026, taking place Thursday, September 24, at the Las Vegas Convention Center.
Designed to introduce students to the limitless career opportunities across the printing industry, this year's program will feature enhanced career development programming, expanded mentorship opportunities, and greater one-on-one engagement with industry professionals throughout the day's activities.
Dublin, Ireland – July 2026 – digitalprint.ie, Ireland's trusted supplier of wide format printing equipment and media, has completed the delivery and installation of two Epson SureColor S9100 printers to long-standing customer iGraphic, based in Newtownards.
The installation, which required careful planning and specialist logistics to position both machines on a first-floor mezzanine, marks another milestone in a valued, ongoing partnership.
Johannesburg – July – 2026 Experience the latest digital printing, vehicle wrapping and paint protection films at the FESPA Africa and Sign Africa Johannesburg Expo, where industry meets opportunity.
The event is taking place from 8-10 September 2026.
Arhus – Denmark – July 2026 – Mikkelsen Innovation ApS has announced that its FASTSEWN™ 3.3M has been named the recipient of the 2026 Pinnacle Award in the Technology category by PRINTING United Alliance.
The recognition highlights the machine's role in automating the final manual step in textile graphics production, combining automated sewing and laser cutting with keder application for silicone edge graphics (SEG).
Barbieri electronics is strengthening its leadership team as the company prepares for its next phase of development.
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Altrincham – Cheshire – July 2026 - Friedmans Ltd and Funki Fabrics have announced the arrival of new print designs, expanding their existing collection with a fresh range of trend-led prints available across a broad selection of premium fabric bases.
The launch offers fashion designers, production teams, and creative professionals a timely opportunity to explore new possibilities for their upcoming collections.
Leicestershire - July 2026 – Vivid Laminating Technologies is pleased to announce that HG Graphics, a leading provider of building signage and vehicle wraps across Yorkshire and the UK, has invested in a fully integrated print and cutting solution combining the VelobladeNexus with the latest Onyx Graphics software.
The installation, supplied and commissioned by Vivid Laminating Technologies, sees three printers feeding directly into HG Graphics' new VelobladeNexus with auto tool change — all operating under full Onyx Graphics software integration. The solution was delivered and set up on-site as part of a complete, ready-to-run installation
Wednesday, July 29, 2026 - RENNES, France—Pointcarre, the French American textile CAD company known for its jacquard and dobby weaving software, has developed a new module dedicated to wall to wall carpet and carpet tile design.
The launch addresses a gap left when APSO, the longtime CAD platform for the tufting industry, discontinued its software more than two years ago, leaving mills and carpet designers without a clear path forward.
Accrington, UK, July 29, 2026: Soyang Europe has expanded its direct-to-film (DTF) range with the launch of a paper-based transfer media that offers an environmentally conscious alternative to conventional PET transfer film.
Named Soyang DTF Paper, the new product is a single-sided release-coated transfer paper featuring anti-static treatment and a hot-peel release.
Designed for use with digital inkjet DTF printers running water-based pigment inks, the media can be recycled through standard paper waste streams, helping print businesses reduce plastic waste.
London – July 2026 – Perfect Colours, a leader in print management solutions, has highlighted the availability of Print Factory, a unified Raster Image Processor (RIP) designed to deliver consistent, high-quality colour output across multiple printers.
The solution addresses one of the print industry's most persistent challenges: maintaining colour accuracy and consistency across different devices and workflows.
Las Vegas, NV – July 2026 – Caldera, a leading provider of print workflow software solutions, has announced its participation in PRINTING United Expo 2026, taking place 23–25 September 2026 at the Las Vegas Convention Center.
Visitors can find Caldera at Booth C1469, where the company will showcase its latest innovations in print workflow automation, colour management, and apparel decoration.
Ghent – Belgium – July 2026 – Kongsberg Precision Cutting Systems (Kongsberg PCS), a leading provider of digital cutting solutions, is calling on print, signage, and packaging businesses to embrace advanced materials as a strategic pathway to new markets, higher-value products, and more sustainable growth.
As competitive pressures intensify across the manufacturing sector, Kongsberg PCS is positioning its versatile, high-performance digital cutting solutions as essential tools for businesses looking to expand their capabilities and future-proof their operations.
The company's message is clear: businesses that invest in advanced material processing today are best placed to lead their industries tomorrow.
Bracknell – Berkshire-July 2026 – UFABRIK’s Soft Blackback Textile, a premium material engineered for tension frames, interiors, retail environments, exhibitions, soft signage, and beyond.
Designed to meet the exacting demands of modern display and signage professionals, the new textile sets a new benchmark for quality, versatility, and performance in the industry
Crewe, UK – July 2026 – Hybrid Services Ltd, the UK's leading Mimaki distributor, has announced two dedicated demonstration weeks at its Crewe showroom this August, giving businesses across the print industry the opportunity to explore the latest Mimaki technology firsthand.
Taking place from 3rd to 7th August and 17th to 21st August 2026, the August Demo Weeks are designed to help businesses make informed investment decisions by experiencing Mimaki's wide format print solutions in a hands-on, pressure-free environment.
Florida – July - 2026 – Agfa Inkjet Solutions has announced its return as a Keynote Sponsor of the 2026 Wide Format Summit, marking the sixth consecutive year the company has supported the industry's premier gathering.
The event is scheduled to take place from 27 to 29 July 2026 at the Hyatt Regency Coconut Point Resort and Spa in Bonita Springs, Florida.