How to make custom merch: a step-by-step guide for brands and creators
Branded merchandise has evolved far beyond giveaways at events. From startup teams to creator communities and global brands, merch has become a way to build community and strengthen brand identity. But with so many decisions to make, from product choice to design and production, getting started can feel overwhelming. This guide breaks the process into clear, actionable steps, helping you create high quality custom apparel that reflects your identity and stands out for the right reasons.
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Step 1: Define your goal and audience
Every successful piece of custom merch starts with a clear purpose. Are you trying to build culture inside your company, deepen ties with your community, or make your brand more visible? Defining this shapes the outcome.
For example:
Restaurants and cafés might create branded t-shirts, hoodies, or tote bags for staff uniforms or to sell at the counter.
Creators often release custom t-shirts or hoodies as drops to connect with their fans.
Corporate brands may choose tote bags or caps for conferences, events, or client gifting.
When your goals are clear, you’ll create premium custom apparel that feels intentional, giving your audience something to value rather than discard.
Step 2: Choose the right products
Not every product delivers the same impact. The right choice depends on how you want your brand to be seen and remembered. At Assembly, our product range spans t-shirts, hoodies, sweatshirts, tote bags and caps, each with distinct strengths.
Custom t-shirts are versatile wardrobe staples, suited to everything from brand launches to event giveaways.
Custom hoodies are higher-value pieces people keep in regular rotation, making them ideal for onboarding or limited community drops.
Custom sweatshirts bridge the gap between casual and refined, with a structured look and soft feel that work in both professional and lifestyle settings.
Branded tote bags are practical and visible, carrying your brand into everyday spaces such as commutes, cafés, and stores.
Custom caps add variety beyond apparel, making them perfect for daily wear or as statement pieces.
When choosing, consider how long you want your branded merch to stay in circulation, how much space your design needs, and what impression each product leaves behind.
Step 3: Select your customisation method
The printing or embroidery method you choose will define not only how your custom branded merchandise looks, but also how it feels and lasts. At Assembly, we offer a range of premium techniques, each with its own strengths:
Screen printing: Vibrant, durable results with precise colour matching. Best for larger orders.
Hybrid printing: Delivers smooth gradients and photographic detail with a durable, professional finish. Great for artwork that needs depth and precision.
Direct Transfer Film (DTF): Produces vibrant prints that stay bright on dark fabrics. A strong choice for short runs with complex designs.
Direct-to-Garment (DTG): Prints directly into cotton for a soft, natural feel. Best for detailed, multi-colour designs on lighter garments.
Embroidery: Adds real thread texture that elevates logos. More costly than print, but conveys craftsmanship and longevity.
3D embroidery: Creates raised designs with depth. Suited for thicker garments such as caps, hoodies, and sweatshirts.
Puff print: A raised, textured finish that adds depth. Creates impact even when logo and garment are the same colour.
Reflective heat transfer: A sleek finish that shines under light or flash. Popular for streetwear, activewear, and uniforms needing visibility.
When comparing methods, think about the impression you want to create, whether it's screen printing for bold designs, embroidery for prestige, or DTG for a softer, natural feel.
Step 4: Mock up your custom branded apparel
With your product and print method chosen, it’s time to bring the design to life. The way you prepare the artwork and preview it makes a big difference to the final result. At Assembly, every design goes through our Studio, where you can upload artwork, explore placement options, and visualise your merch in real time. True-to-scale previews help ensure your logo or artwork lands exactly where you want it. Follow these steps for the best results:
Upload artwork correctly
Use the accepted file formats for your chosen customisation method. Specific requirements are outlined directly in Studio when setting up your design.
Provide Pantone references
Where possible, include Pantone colour codes. These ensure your chosen shade is matched precisely in production, rather than relying on screen colours.
Preview across products
Test your design on different garments, from custom t-shirts to sweatshirts, so you can see how placement, scale, and proportion shift depending on the product.
Step 5: Plan quantities, MOQ, and budget
Once your design is ready, it’s time to plan the practical side: how many units you need, how much flexibility you have with minimums, and how this shapes your budget.
A few things to keep in mind:
Mixing sizes: You can combine sizes (XS to XXL) within the same order, as long as they share the same style and colour.
Choosing methods wisely: At Assembly, DTG and DTF start at 15 pieces, making them useful for small teams or limited drops. Other methods begin at 50 units and suit larger teams or events.
Budget planning: The Assembly price calculator gives instant estimates, so you always know how specifications affect cost before placing an order.
Being clear on quantities upfront helps you balance ambition with practicality, making sure you create branded merch that fits both your goals and your budget.
Step 6: Production and quality control
Once your order is confirmed, production begins. This is where your designs are turned into finished pieces, and it’s also the stage that determines whether your custom apparel feels premium or ends up looking disposable.
During production, three things matter most:
Materials: High-quality fabrics like 100% cotton guarantee comfort and longevity. When combined with garment dyeing, these natural fibres absorb dye evenly, creating rich, consistent colour and a soft, comfortable feel.
Accuracy: Colour consistency and precise artwork placement are essential to ensure your brand identity comes through as intended.
Finishing: Details such as stitching quality and label application give each piece a polished, professional feel.
Choosing the right partner means your merchandise will not only look good, but also uphold your brand standard.
Step 7: Delivery, distribution, and beyond
The last step in your merch journey is making sure it reaches people in the right way. Delivery and distribution shape the experience as much as design and production. For example, corporate merch for events needs to arrive ahead of schedule, while custom apparel for teams or customers should come clean, organised, and easy to distribute.
Choosing a partner that manages the full supply chain helps ensure your order arrives on time and reflects your brand standards. At Assembly, we ship worldwide with economy and priority options to meet different timelines, and every item is folded, labelled, and packaged individually so it arrives presentation-ready.
Conclusion: How to create merchandise for a brand or community
Creating merchandise for a brand or community isn’t just about putting a logo on a product. It’s about starting with clear goals, choosing the right items, and selecting the best customisation method, then moving through design, planning, production, and delivery. Each step matters, because together they determine whether your merch feels like an afterthought or a true extension of your identity.
At Assembly, we bring these steps together in one place, combining premium materials, careful production and an integrated Studio experience. The result is custom branded apparel people want to wear and use.
