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Frequently Asked Questions

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Everything about ordering custom apparel, embroidery and stickers β€” turnaround, files, shipping and our guarantee.

Ordering & Turnaround Artwork & Files Custom Apparel Embroidery Stickers Shipping & Pickup Returns & Guarantee Reorder

🧾Ordering & Turnaround

How long does an order take?
Most custom orders are printed and ready in 3–5 business days after you approve your design. Bigger runs and embroidery can take a little longer β€” we'll always give you a date up front. Need it sooner? Ask about rush service.
Is there a minimum order?
Single shirts & hoodies have no minimum β€” order one or many. Custom stickers start at our smallest sheet (~30 stickers). Bulk apparel pricing kicks in at 10+ pieces. Need a big run? We'll quote it.
Can I order a huge custom or wholesale job?
Absolutely β€” teams, shops, events and brands are our favorite work. Use any builder's "Order direct" form or the Wholesale section and we'll get you a quote.
Where are you located?
We print everything in-house in Madison, Virginia β€” no middleman, no drop-ship warehouse. That's how we keep turnaround fast and quality tight.
Can I reorder something you printed for me before?
Yes β€” that's the easiest order you'll ever place. We keep your print files on record, so just use the reorder form with your order number and we'll email you an invoice for the same job.

🎨Artwork & Files

What file should I upload?
A transparent PNG is best for most prints and stickers. We also take JPG. For embroidery logos, see that section below. Our builders check your resolution live and warn you if a file is too small to print sharp.
What resolution do I need?
Aim for 300 DPI at print size. Our builders show a live color-coded quality meter β€” green is print-ready, yellow/orange means it may look soft, red is too low. A high DPI number alone doesn't guarantee a great print: a blurry or already-upscaled file still prints soft, so start with genuinely sharp art.
Can you fix or enhance my image?
Yes. In the shirt builder you can add AI enhancement to sharpen and upscale a soft file. For anything more involved, send it through the order form and we'll take a look.
Do you offer design help?
We can help with simple cleanups and placement. For a from-scratch design, tell us your idea on the order form and we'll quote the design time.

πŸ‘•Custom Apparel

What printing method do you use?
Full-color DTF (direct-to-film) transfer β€” it prints vivid, full-color art on any garment color, soft to the touch and built to last wash after wash.
What's the biggest print you can do?
Standard print is up to 12" wide; up to 13.5" is available as oversized for a small upcharge. The builder shows the size guides live as you resize.
What sizes and colors are available?
Unisex tees and hoodies in sizes S–3XL and a range of colors β€” pick them right in the builder. See the size chart in the shirt builder for exact measurements.

🧡Embroidery

What can you embroider?
Hats, beanies and polos/shirts β€” add custom text (pick your font and thread color) or send a logo to digitize. Build it in the embroidery builder.
What is "digitizing" β€” and is it extra?
Embroidery machines can't read a normal image β€” they sew from a digitized stitch file that maps every stitch, direction and color. Most shops charge a setup fee to make it; we include digitizing free on your embroidery order. Text you build on-site doesn't need it at all.
Do you take my own stitch file?
Yes β€” if you already have a .DST / .PES / .EXP / .EMB file, upload it and we'll sew straight from it.

🏷️Stickers & Decals

What kind of stickers do you make?
Durable die-cut vinyl stickers with a clean white border, laminated gloss or matte, weatherproof β€” shipped on a roll. Upload one design or many and our builder auto-nests them onto the sheet.
How are stickers priced?
By sheet size β€” pick a sheet (a ~30-sticker sheet starts at $36) and pack as many designs as you want onto it. Bigger sheets cost less per sticker, and shipping is free. The builder shows your total live.
Will my sticker be cut to its shape?
Yes β€” upload a transparent PNG trimmed to your design and we die-cut to that shape with a 2 mm white border. Not transparent? The builder can remove a solid background for you. Need help prepping a file? Ask on the order form.

πŸ“¦Shipping & Pickup

How much is shipping?
Single & retail orders always ship free β€” no minimum. Bulk orders are quoted (we include shipping or local Virginia delivery in the quote). Everything is printed and shipped from Madison, VA.
Can I pick up locally?
Yes β€” free local pickup by appointment in Madison or Culpeper, VA. Message us after you order and we'll set a time & easy meet-up spot when it's ready.
Do you deliver locally?
For bulk orders we offer delivery quotes across Virginia β€” great for teams, shops and events. Or grab free pickup by appointment in Madison or Culpeper, VA. Ask for a delivery quote when you order.
Do you offer rush or expedited?
Yes, rush production and expedited shipping are available on most orders β€” ask when you order or note it on the form.

βœ…Returns & Our Guarantee

What's your quality guarantee?
We stand behind every print. If your order arrives defective or not what we agreed to make, we'll reprint it or refund it β€” just send a photo within 14 days. That's the whole point of checking your resolution before we print.
Can I return a custom order?
Because custom and personalized items are made just for you, they can't be returned for buyer's remorse β€” but defects and our mistakes are always covered by the guarantee above.
What about the retail graphic tees?
Unworn, unwashed stock tees can be exchanged or returned within 30 days. Reach out and we'll sort it out.

πŸ”Reorder a Past Job

Ordered with us before? We keep your print files on record. Drop your order number and email below β€” we'll pull the job and email you an invoice to run it again (add a note if you want changes, like more shirts or a different color).

Still have a question?

Real humans in Virginia β€” we'll get back to you fast.

Email Sales@bigchatosapparel.com