Custom merch is made through a step-by-step production process: concept strategy, design prep, sourcing and manufacturing, sampling, quality control, and logistics. A full-service merch partner manages these stages end-to-end to ensure accuracy, quality, and on-time delivery. TVP NYC oversees the complete custom merch production process for brands and organizations.
Custom merchandise looks simple on the surface, pick a product, add a logo, ship it out. But high-quality merch that people actually want to wear, use, and keep requires a structured, multi-step production process. That process includes concept development, product strategy, design, sourcing, sampling, manufacturing, quality control, and logistics.
When done well, custom merch becomes more than branded items. It becomes a brand experience.
At TVP NYC, we manage the full end-to-end custom merch process for brands, organizations, and teams, making sure every step is accurate, consistent, and aligned with your goals.
What Is Custom Merchandise?
Custom merchandise (custom merch) refers to branded products created specifically for a business, campaign, event, or organization. This can include apparel (t-shirts, hoodies, hats), accessories (tote bags, water bottles), office items, packaging, and fully custom manufactured goods.
Common Use Cases for Custom Merch
Custom merch is used across industries for:
- Brand campaigns +product launches
- Events, conferences, and premieres
- Internal culture building (employee welcome kits, team merch)
- Influencer + creator partnerships
- Retail or eCommerce collections
- Nonprofit fundraising and donor gifts
- Press kits and media mailers
You may be asking:
What’s the difference between custom merch and promotional products?
Promotional products are often standard items with a logo added. Custom merch goes further, through curated product selection, premium decoration, custom labeling, packaging, and in some cases, fully custom manufacturing.
Step 1 – Concept + Product Strategy
Every successful merch project starts with strategy. This is the stage where we define what the merch is for and what success looks like.
Brand Goals
Before selecting products or design styles, we clarify:
- Is this merch meant to drive awareness, reward loyalty, or generate revenue?
- Is it for staff, VIPs, or a public release?
- Is the priority premium quality, fast turnaround, budget efficiency, or sustainability?
Audience Considerations
Your merch should match the people receiving it:
- What do they actually wear or use?
- What sizes and fits matter?
- What colors and aesthetics align with their tastes?
- What “feels like” your brand?
Product Selection
This is where strategy becomes tangible. We help determine the best merch formats based on:
- Brand identity
- Occasion (event, ongoing program, seasonal campaign)
- Budget range
- Lead time
- Distribution method (direct-to-consumer, bulk delivery, multi-location shipping)
Pro tip: The best merch is something people choose to keep, not something they feel obligated to accept.
You may be asking:
How long does custom merch production take?
It depends on the product type and sourcing route. Domestic production is often faster, while overseas production typically takes longer but allows more customization. If you have a deadline, planning backward from your event date is essential.
Step 2 – Design + Artwork Preparation
Design is not just about making something look good, it’s about making it printable, manufacturable, and consistent.
Logo Placement + Layout
We map out:
- Front/back placement
- Sleeve, tag, or hem branding
- Center chest vs left chest vs oversized formats
- Embroidery locations and constraints
Print + Decoration Techniques
Different decoration techniques impact cost, durability, and aesthetics. Common methods include:
- Screen printing (ideal for bulk and bold graphics)
- Embroidery (premium look; best for hats and outerwear)
- DTG / DTF (great for complex artwork and smaller runs)
- Heat transfer / patches / appliqué (stylized looks)
- Custom labels + neck prints (retail-grade finishing)
TVP NYC helps match design choices with the right production method to avoid surprises later.
Brand Guidelines + Consistency
We align artwork with:
- Pantone or brand color standards
- Typography and spacing rules
- Approved logo files and formats (vector vs raster)
- Overall brand tone (minimal, bold, luxury, playful)
This stage is where we ensure your merch looks like it came from your brand, not a generic print shop template.
Step 3 – Sourcing + Manufacturing
This stage determines the quality, price, timeline, and reliability of the entire project.
Domestic vs Overseas Production
Both have advantages. Choosing the right option depends on your timeline, budget, and complexity.
Domestic production may offer:
- Faster turnarounds
- Easier communication
- Lower minimums
- Simpler approvals
Overseas production may offer:
- Lower cost per unit at scale
- More customization options (custom fabric, trims, unique construction)
- Higher production capacity for large campaigns
TVP NYC helps you choose the best manufacturing path based on what you’re producing and how quickly you need it. Also, because we are your point of contact, we help you every step of the way, communicating clearly and efficiently, whether your merch is produced locally or overseas.
Material Selection
Material choices affect how your merch feels and how long it lasts. We source based on:
- Fabric weight (lightweight vs heavyweight)
- Sustainability preferences
- Durability requirements
- Seasonality
- Intended wear and usage
Ethical and Quality Considerations
We prioritize partners that align with best practices, especially for brands that need:
- Responsible sourcing
- Ethical labor standards
- Reliable quality control
- Consistent sizing and finishing
This is where a full-service partner adds major value: sourcing isn’t just “finding a vendor,” it’s ensuring the vendor consistently delivers.
Step 4 – Sampling + Approvals
Samples reduce risk, protect brand integrity, and prevent expensive mistakes.
Why Samples Matter
Even the best artwork can change slightly once it hits real fabric or materials. Sampling ensures:
- Color accuracy
- Correct size and placement
- Proper ink or thread match
- Quality of garment or product construction
What Gets Reviewed
During sampling, we check:
- Print alignment and sharpness
- Stitch density (for embroidery)
- Material and fit accuracy
- Labeling and packaging details
- Overall “does this feel premium?” factor
After samples are approved, production can move forward with confidence.
You may be asking:
Do I need samples?
If quality matters (and it usually does), yes. Samples significantly reduce risk and ensure the final product matches expectations before full production begins.
Step 5 – Quality Control
Quality control (QC) is where brands protect their reputation. A single batch of flawed merch can cost time, money, and trust.
Inspection Standards
TVP NYC coordinates and manages QC checks across:
- Vendor inspections
- Random unit sampling
- Full-order QC when required
- Packaging and labeling review
Color, Print, and Construction Checks
QC typically includes:
- Color consistency across units
- Print cracking, fading, or misregistration
- Seam quality and sizing accuracy
- Product defects (stains, tears, weak stitching)
- Fold, packout, and labeling standards
This step ensures what arrives at your doorstep matches what you approved.
Step 6 – Logistics + Fulfillment
After manufacturing, the job isn’t done. Shipping, warehousing, and fulfillment are where timelines often break, unless managed properly.
Warehousing
Depending on your project, merch may go to:
- Your office or event venue
- A fulfillment partner
- A warehouse for staged shipping
- Multiple locations (regional teams, chapters, talent, VIPs)
Shipping Coordination
We manage timelines and logistics including:
- Freight scheduling
- Customs coordination (when applicable)
- Last-mile delivery
- Split shipments and staggered rollouts
Delivery Timelines
Timeline depends on:
- Product complexity
- Production location (domestic vs overseas)
- Number of SKUs and customization points
- Shipping method and destination
TVP NYC builds timelines backward from your deadlines and proactively manages risk so you don’t get stuck with merch arriving after the event.
You may be asking:
Can TVP NYC handle shipping and fulfillment?
Yes. TVP NYC manages logistics, warehousing coordination, and delivery timelines so your merch arrives where it needs to, on time and properly organized.
How TVP NYC Manages This Process End-to-End
If you’ve ever tried to produce custom merch with multiple vendors, you already know the challenge: communication gaps, missed deadlines, inconsistent quality, and unclear accountability.
TVP NYC solves that by managing the full process, from concept to delivery, with one centralized team.
Centralized Communication
Instead of coordinating between designers, factories, printers, and shipping providers, you work with one partner that manages the entire chain.
Timeline Management
We create a production roadmap with clear milestones, approvals, and contingency planning, so deadlines stay realistic and projects stay on track.
Risk Reduction
Because we manage sourcing, sampling, QC, and logistics, we help prevent the most common merch problems:
- Misprints and incorrect placements
- Inaccurate colors
- Sizing inconsistency
- Vendor delays
- Shipping surprises
- Last-minute budget overages
In short: we make custom merch production feel organized, predictable, and brand-worthy.
Ready to Create Custom Merch Without the Headaches?
If you want custom merch that feels elevated, consistent, and professionally managed, from concept and design through sourcing, production, and delivery, TVP NYC can help.
We oversee the complete custom merch production process for brands and organizations, ensuring accuracy, quality, and a seamless experience.
