A Blueprint for Mastering High-Value, On-Demand Digital Garment Decoration
Today’s consumers do not just want a printed t-shirt. They demand high-quality, sustainable, bespoke products delivered with the frictionless transparency of an Uber ride or an Amazon parcel.
“To capture premium margins in this crowded, accelerating marketplace, garment decorators must move beyond apparel and embrace a new frontier of end-to-end automation, hybrid technologies, and ethical production”.
WRITTEN BY FESPA TEXTILE AMBASSADOR DEBBIE MCKEEGAN
The global printed garment decoration industry is scaling at an unprecedented pace. Print-on-demand businesses are experiencing phenomenal acceleration - some industry leaders are reporting 35% to 40% year-on-year growth.
Yet, beneath this explosive growth lies a critical industry challenge: the traditional manufacturing model is fundamentally broken.
Today’s consumers do not just want a printed t-shirt. They demand high-quality, sustainable, bespoke products delivered with the frictionless transparency of an Uber ride or an Amazon parcel.
To capture premium margins in this crowded, accelerating marketplace, garment decorators must move beyond apparel and embrace a new frontier of end-to-end automation, hybrid technologies, and ethical production. As noted by Joao Sa of ROQ International "There's still room for screen printing for large volume orders. We've seen a transition in the last 10 years for hybrid systems leveraging both screen and digital technologies. We've witnessed a transition where screen printers are crossing the border to mix between digital and screen. We've also seen that digital continues to accelerate…at the same level that order batches are being reduced. We are at a point where hybrid has an important role as an apparel decoration tool in this evolving marketplace”.
Drawing upon insights from leading experts across the garment decoration sector in our recent FESPA webinar we welcomed industry experts in fulfilment, hardware, and digital software:
Phil Oakley - Snuggle Ltd
Gerard Buch - InEdit
Dave Conner - Stahls/Fulfill Engine
Joao Sa - ROQ International
Here is the blueprint for mastering the next generation of on-demand digital garment decoration:
The Labour Crisis and the need for Automation
Let us address the uncomfortable truth: the apparel sector is facing a severe labour leak. Traditional, manual print environments are no longer attractive to the modern workforce. However, this crisis presents a distinct opportunity for forward-thinking businesses.
To build an agile, lean, and profitable business, we must ruthlessly differentiate between "task work" and "knowledge work". Highly paid staff manually copying and pasting order details from a spreadsheet into a production schedule is a devastating waste of capital. By integrating advanced automation, businesses can dramatically reduce manpower on repetitive tasks, across admin, pre-press, printed production and fulfilment.
This is not about replacing humans; it is about elevating them. When we automate the mundane - such as using API integrations to pull order data seamlessly from an e-commerce platform directly to the print floor, we free our workforce to focus on high-value, creative, and strategic knowledge work.
Interoperability: The True Bottleneck
The most significant technological advancement your business needs to prioritise right now isn't necessarily a faster printer; it is interoperability.
The modern print-on-demand ecosystem is highly fragmented. There is no single platform that dominates the market. Decorators must integrate with various e-commerce sites, blank suppliers, shipping services, and hardware systems. The true bottleneck in production often occurs during the hand-off process between these disparate systems.
The Solution: Smarter, connected systems. Innovative setups now utilise dynamic QR code scanning. When a blank garment enters the shop floor, a quick scan can automatically pull the exact file, the specific thread colours for embroidery, or the precise pre-treat and white under-base settings for a Direct-to-Garment (DTG) or Direct-to-Film (DTF) printer. This eliminates the "tribal knowledge" previously restricted to one or two veteran machine operators and democratises production efficiency across the entire workforce.
Eradicating Waste: A Sustainable Advantage
Sustainability is the default; it is an operational standard. Brands are increasingly demanding total transparency in their supply chains. By example; garment decorator and on-demand apparel supplier Snuggle ltd. recently completed their first audit using the Sedex SMETA platform to audit ethical workforce and health and safety standards Phil Oakley confirmed. "If you cannot provide a transparent, ethical supply chain, you will lose the contract".
Furthermore, sustainability extends directly to your consumables. "In traditional setups, the sampling process and misprints represent a catastrophic waste of ink, media, and time. By implementing robust software workflows - where advanced RIP software handles complex colour matching and white-ink layers autonomously - we can guarantee that the first print is identical to the thousandth" Gerard Buch of InEdit commented. Eliminating the need for manual sampling and reducing misprints is one of the most effective ways to lower carbon footprints whilst simultaneously protecting profit margins.
Disrupting the Market: Dimensional Decoration and the "Uber" Experience
To capture true premium margins, businesses must offer something disruptive. We are now seeing the advent of hybrid technologies, such as Liquid 3D - a patented process combining 3D and digital UV printing to create full-colour, textured, dimensional prints without the setup charges or minimum order quantities of traditional emblems.
However, the ultimate differentiator is the customer experience said Phil Oakley. "The gold standard for garment decoration is the "Uber model": full transparency, predictable pricing, and real-time tracking from the moment the artwork is verified to the second the product arrives at the customer's door".
Actionable Insights for Future-Proofing Your Business
To thrive in this evolving landscape, business leaders must take immediate action:
Audit Your Touchpoints: Map out your entire workflow from order intake to dispatch. Identify every manual handoff and invest in software that automates these transitions.
Embrace Hybrid Technologies: Do not limit yourself to DTG or DTF. Look into hybrid screen-to-digital systems and dimensional printing (like UV emblems) to offer high-value, unique customisations that command premium prices.
Standardise for Sustainability: Implement smart RIP software that standardise ink layers and colour profiles across all substrates. You will drastically reduce ink waste and eliminate the costly trial-and-error sampling phase.
Prepare for Transparency Audits: Ensure your supply chain and workforce practices meet global ethical standards (e.g., Sedex). Big brands demand this visibility before they will sign a contract.
Elevate the Customer Experience: Build a client-facing portal that offers real-time tracking and artwork validation. Empower your customers to know exactly what they are getting and when.
The future of garment decoration is complex, fast-paced, and wildly exciting. The technology to achieve seamless, sustainable, and highly profitable on-demand production exists today. It is up to you to integrate it. Watch the full webinar here:
Visit Fespa Global Expo 2026 in Barcelona 19th-22nd May
Are you ready to elevate your apparel production workflow and capture high-value margins? Discover how tailored automation and digital decoration solutions can transform your business at the Fespa Global Expo in Barcelona, 19th - 22nd May 2026
Don’t miss this unparalleled opportunity to shape your future in the print and product personalisation landscape.
From Helsinki's printing mill to Paris's Le Marais, discover how Marimekko is scaling a design-led brand with purpose, craft, and bold innovation.
But what makes Marimekko's story compelling is not just its aesthetic legacy?
The word "toxic" carries weight. It conjures danger, harm, and things best avoided.
“Yet in the textile industry - Where between 3,000 and 10,000 chemicals move through the supply chain, a reflexive fear of the term is one of our biggest obstacles to progress.”
This article distils the key takeaways and what buyers, designers, and brands should be asking right now.
What Is the Digital Product Passport?
At its core, a Digital Product Passport is a digital record attached to a physical product - For a printed textile product, this means the DPP would capture data on the substrate, inks and dyes used, the printing process and technology, chemical compliance, environmental impact (including water and energy use), supply chain traceability, and end-of-life instructions.
The Market Gap that Changed Everything
Future Fashion was founded in 2019, timed deliberately to coincide with a pivotal moment in global textile technology: the commercial launch of the EFI Reggiani BOLT Single-Pass digital printing system.
The founders recognised that single-pass architecture had fundamentally changed what was industrially possible - and that Pakistan's domestic market had yet to catch up.
Print is no longer defined by the inefficiencies that once characterised it…as advances in production processes and technology have significantly improved its environmental performance.
Taran Rai, Corporate Sustainability Manager at Epson explains why?
The story of what happens when young designers access digital technology is still being written.
What once was a theoretical sustainability goal seems to have shifted into an active regulatory reality.
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.”
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.”
Pointcarre, a leading provider of AI-powered textile CAD software, has highlighted its new AI-driven image upscaling feature designed to help textile designers restore and enlarge low-resolution pattern files without compromising design integrity.
The new capability addresses one of the most persistent challenges in the textile industry: working with legacy or low-quality design assets.
Klagenfurt, Austria – September 2, 2026 – J. Zimmer Maschinenbau GmbH Klagenfurt and J. Zimmer Maschinenbau GmbH Kufstein | Digital Printing Systems have announced the launch of "Zimmer 2028", a strategic transformation initiative that will unite the two operating companies into a single, unified organisation effective January 1st, 2028.
The initiative represents a decisive response to evolving market demands and increasing economic pressures facing the industrial printing and textile machinery sector.
Birmingham, UK – September 2026 – Epson UK & Ireland will be exhibiting at The Print Show 2026, taking place at the NEC Birmingham from 29 September to 1 October 2026.
Visitors can find Epson at Stand S130, where the company will present live demonstrations of its latest professional printing technologies across UV, Direct-to-Garment (DTG), Direct-to-Film (DTF), and flatbed printing.
Aarhus, DK & Milwaukee, WI — September 2, 2026 — FASTSEWN will showcase the next generation of its flatbed automated textile finishing at PRINTING United 2026 with the U.S. debut demonstration of its innovative full 3.3M width StitchNCut™ flatbed sewing and laser cutting solution.
This solution is designed specifically for high-volume production of Silicone Edge Graphics (SEG), pillowcase graphics, and other grand-format and industrial textile applications.
The centerpiece of the launch will be live remote demonstrations from FASTSEWN’s headquarters, where attendees will see the company’s full-size StitchNCut 3.3-meter automated flatbed sewing and laser cutting system producing finished SEG graphics and pillow graphics under real market-based production conditions.
Newtown PA – 11 August 2026 – Hybrid Software will showcase the technologies shaping the future of print production at PRINTING United Expo 2026. At booth C1371, visitors will see how artificial intelligence, GPU-native rendering, workflow automation and advanced colour management are improving productivity, quality and efficiency across print production.
Demonstrations will span the Hybrid Software Group portfolio, including Labels & Packaging, Brandz, Helix, Color, Xitron and Meteor Inkjet.
For sticker businesses, moving from offline to online sales is more than simply adding a new sales channel.
It requires a well-structured process that makes product discovery, customization, ordering, and fulfillment as seamless as possible for the customer.
According to Wacław Mostowski, CRO & Co-founder of Antigro Designer, when implemented effectively, online sales can expand market reach, improve operational efficiency, and create new opportunities for scalable growth.
A strong e-commerce presence allows print businesses to reach customers beyond their local market while creating a more accessible and convenient buying experience.
Crewe , United Kingdom – September 2026 – Hybrid Services Ltd, the exclusive distributor of Mimaki technology across the UK and Ireland, has confirmed that its dedicated Mimaki showroom remains open to visitors five days a week following the successful conclusion of its recent Demo Weeks event.
The Demo Weeks programme welcomed a wide range of visitors to the showroom, giving attendees the opportunity to explore the latest print technology, discover new ideas and advance their Mimaki journey.
With the event now complete, Hybrid Services is reminding those who were unable to attend that the showroom continues to operate on an ongoing basis.
Open Monday to Friday, 9am to 5pm, the Mimaki showroom houses an extensive range of technology spanning sign and graphics, industrial printing, textile and apparel, and 3D printing.
Braintree, Essex – 2 September 2026 – Venture Banners, a leading UK trade-only large-format print supplier, will highlight its expanding textile signage range, including its newest solutions, at The Print Show 2026, taking place from 29 September to 1 October at the NEC, Birmingham.
Hamamatsu, Japan – 2 September 2026 – Roland DG Corporation, the world's leading provider of wide-format digital printing solutions, today announced the launch of the TrueVis AG-640, a next-generation 64-inch latex printer/cutter that expands what's possible with latex printing.
Combining low running costs, high output quality, expanded colours, dense white ink, and integrated contour cutting, the AG-640 helps print professionals move beyond traditional latex limits to take on more profitable work with confidence
Leicester – UK – September 2nd 2026 - VeriVide have launched UltraView60, a new, compact, cost-effective colour assessment cabinet that expands the existing UltraView product range and makes its tuneable LED technology accessible to more organisations.
Developed as a lower cost entry into the UltraView range, UltraView60 gives businesses, who have limited space available, the opportunity to benefit from the features and colour assessment capabilities in VeriVide’s UltraView technology.
Anglesey – September 2026 – Nova Chrome UK, one of the UK's longest-standing suppliers of dye sublimation printing solutions, has announced it will exhibit at The Print Show, taking place at NEC Birmingham.
Visitors can find the company at Stand P240, Hall 1, where its specialists will showcase the latest sublimation products and equipment.
Leicester UK – September 2026 – Vivid Laminating Technologies Ltd has announced the delivery of its latest Veloblade Nexus cutting system this week, produced for Krit Patel and Printvision (UK) Ltd.
The milestone marks another significant step forward in the company's mission to lead the print finishing industry with precision engineering and innovative technology.
The Veloblade Nexus represents one of Vivid Laminating Technologies' most advanced digital cutting solutions to date.
Telford, UK – September 2026 – China Print Supplies UK Ltd invites businesses considering an investment in new print equipment to experience a range of machines in action at its showroom, where prospective buyers can assess print quality, ask questions, and test their own materials before committing to a purchase.
As demand for high-quality, versatile printing solutions continues to grow, seeing equipment perform under real conditions has become an increasingly valuable step in the buying process.
China Print Supplies is addressing this need by offering hands-on access to a selection of its latest demonstration machines, allowing customers to make informed decisions with confidence.
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
Comun Nuovo, Lombardy – September , 2026 – EFI has announced its EFI Reggiani pigment printing solutions, a suite of integrated digital technologies designed to help textile producers achieve faster turnaround, greater flexibility, and more sustainable production.
The announcement responds to mounting industry pressure for cleaner, more efficient manufacturing without compromising on quality or profitability.
Las Vegas, NV – August 2026 – Agfa will return to PRINTING United Expo 2026, one of the printing industry's most important events, to connect with print professionals from across North America and beyond.
The company will exhibit at Booths 1149 and 1161 at the Las Vegas Convention Centre from 23–25 September 2026.
At the show, Agfa will demonstrate how its latest inkjet solutions help businesses increase productivity, expand application possibilities, and stay ahead in a rapidly evolving print market.
Geretsried, Bavaria, August 2026 – Rudolf has introduced RUCO®-THERM PCM BIO MFT, a bio-based textile finishing technology that brings intelligent thermoregulation to functional apparel, helping hikers stay comfortable as temperatures rise and fall on the trail.
London, UK – August 2026 – The Royal College of Art (RCA) has announced the launch of the fourth RCA x Design for Good Academy, an ambitious live online short course that, for the first time, will open its places to the public alongside Design for Good alliance members and RCA students.
The programme begins in October 2026 and runs until March 2027.
Las Vegas, NV – August 2026 – Sun Chemical today announced its participation in PRINTING United Expo 2026, taking place 23-25 September 2026 at the Las Vegas Convention Centre.
Visitors are invited to booth C2880, where the company will present its latest advances in digital ink, textile, industrial, and sustainability-focused printing solutions designed to help printers transform their businesses.
At the heart of Sun Chemical's presence is a commitment to helping customers improve print quality, enhance sustainability, and optimise productivity.
Peterborough – August 2026 – The addition of embroidery to Snuggle Ltd’s in-house embellishment services, united DTF, DTG, Sublimation, UV and embroidery under a single roof at its UK headquarters.
The move positioned the company as one of the most comprehensive garment decoration operations in the industry.
The decision to invest in embroidery was driven directly by customer demand.
Milan, Italy – 26 August 2026 – Viscom, the international event dedicated to technologies, applications and materials for visual communication and the graphic arts, has revealed the key themes shaping its 2026 Conference programme.
Taking place on 28 and 29 October at the Allianz MiCo Convention Center in Milan, the event will explore how technological innovation, creativity and design capabilities are converging to transform the industry.
With its new Exhibition & Conference format, Viscom is strengthening its role as a hub for visual communication in Italy.
Matthews – NC – August 2026 – Fisher Textiles has announced the launch of its Enviro-Tex® fabric line, a range of sustainable textiles crafted from post-consumer recycled PET bottles.
The new offering delivers the quality, stretch, durability, and print performance customers expect, while helping reduce environmental impact across a wide variety of applications.
Enviro-Tex® is designed to meet the growing demand for sustainable materials without compromising on graphic quality.
Dubai, UAE – August 2026 – FESPA Middle East has announced FLEX, the FESPA Leadership Exchange, a landmark gathering of the print and signage industry's most influential decision-makers.
Taking place in Dubai, UAE, on 26 November 2026, the event will bring together the leaders shaping the future of the sector to exchange ideas, share perspectives and define the opportunities ahead.
As the market continues to evolve, FLEX responds to a clear need: the most valuable conversations happen among those driving change
Birmingham UK – August 2026 - Epson will showcase its latest ColorWorks colour-on-demand label printing solutions at PPMA Show 2026, taking place from 22–24 September at the NEC Birmingham.
Visitors to Epson’s stand (A54, Hall 5) will be able to discover how businesses can transform their labelling processes through in-house, full-colour label production that delivers greater flexibility, lower costs and reduced waste.
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.
WILMINGTON, Del., August 2026 – – DuPont has announced that its Artistri® Digital Printing Solutions are driving the next era of industrial direct-to-film (DTF) printing, moving beyond ink innovation to tackle the process challenges that now define productivity at scale.
Porthmadog, Wales – August 2026 – Vivid Laminating Technologies Ltd has completed the installation of its Razar print finishing system at Snowdonia Design & Print, marking the first Razar installation outside of England.
The milestone represents a significant step in the growing adoption of advanced, versatile finishing technology across the UK print sector.
Described as the "swiss army knife of print finishing", the Razar system brings a suite of high-precision capabilities to the Porthmadog-based printer
Sheffield, UK – Perfect Colours has been appointed the official UK distributor for Platinum Technologies International, the manufacturer formerly known as Liyu Technologies.
Announced in May at FESPA 2026, the partnership gives UK print businesses direct access to Platinum's full range of industrial large-format systems, backed by Perfect Colours' nationwide sales, installation, training, and engineering support.
Wednesday, August 26, 2026 - Richmond, VA: Drytac, the leading international manufacturer of self-adhesive materials for the large-format print and signage markets, is delighted to announce its plans for PRINTING United Expo 2026.
As Drytac continues its 50th anniversary celebrations, visitors will have the opportunity to experience new products, award-winning solutions and live applications across the show floor, highlighting five decades of expertise in adhesive science and coated media