How to customise polo shirts for printing in Australia: Best methods & tips

There’s something about a sharp, branded polo that just works. Whether you’re kitting out a corporate team, a junior footy squad, or handing out merch at an event, custom polo shirts strike that rare balance between polished and practical. They’re comfy, breathable, and way more versatile than your average uniform or promo tee.

But here’s the catch—not all custom polos are created equal. The fabric you choose, the printing method, even where you place your logo can make or break the final result.

So, how do you make sure your custom polo shirts in Australia stand out for all the right reasons? Let’s break it down.

Why choose custom polo shirts for your brand or team?

Polo shirts have been a go-to in the branded apparel game for decades—and for good reason. They walk that fine line between casual and professional. Great for Friday client meetings, warehouse floor work, or repping your brand at trade shows.

Here’s why branded polos are such a crowd favourite:

• Comfort meets polish– Buttoned collars and breathable materials give them a clean, athletic look.
• Easy to wear and re-wear – They’re the kind of uniform staff wantto keep on.
• Unisex appeal – Most styles come in a wide size range and flattering cuts.
• Budget-friendly– Cost-effective in bulk with long-lasting wear.
• Versatile for different settings– From gym floors to golf days to cafés.

Think of them as your brand’s walking billboard, with more stretch and fewer eye-rolls than a stiff dress shirt.

Top printing methods: screen printing, DTG, heat transfer, embroidery

Now we’re into the good stuff. You’ve chosen polo shirts. But how should you get your logo on them?

Here’s a run-through of Australia's most popular polo shirt printing methods, plus the pros and cons of each.

1. Screen printing

This method uses stencils (screens) to apply ink directly onto fabric.

• Best for:Bold, simple logos in large batches.
• Pros:Affordable for big runs, vibrant colours, good durability.
• Cons:Less detail possible, can crack over time on stretch fabrics.

2. Direct-to-Garment (DTG) printing

Think of DTG as the inkjet printer for clothes—great for detailed, colourful designs.

• Best for:Full-colour graphics or small orders.
• Pros: Photorealistic detail, fast turnaround for one-offs.
• Cons: Works best on cotton, not ideal for moisture-wicking polos.

3. Heat transfer vinyl or digital transfer

Designs are printed onto special paper, then heat-pressed onto the fabric.

• Best for: Short runs, detailed logos, or event merch.
• Pros:Flexible, vibrant, works on various fabrics.
• Cons: May peel with heavy washing, especially on activewear.

4. Embroidery

The gold standard for that stitched, professional finish, especially on collared garments.

• Best for:Corporate uniforms, clubs, or premium branded polos.
• Pros:Durable, classy, won’t fade or crack.
• Cons:Costs more per unit, less suited to highly detailed images.

Not sure which to choose? A good rule of thumb: if you want texture and longevity, embroidery wins. Screen or heat transfer might be the go if you’re chasing colour and detail on a budget.

Need a quick quote? Fill out our online quote form now. We’ll get back to you with pricing and timeframes that match your needs.

How to select the right fabric and fit for printing

It’s easy to focus on the logo and forget about the shirt itself, but trust us, fabric choice matters just as much.

Here’s what to consider when selecting your polos:

• Cotton– Soft, breathable, ideal for embroidery or screen printing.
• Polyester– Lightweight, moisture-wicking (great for sports or hospitality) but less print-friendly.
• Cotton/poly blends– The best of both worlds—easy to wear and print on.
• Piqué knit – That classic, textured polo fabric (great for embroidery).
• Jersey knit– Smoother, stretchier, more casual.

And don’t forget fit! Most brands offer regular, slim, and relaxed cuts—so think about who will wear them. A fashion startup might lean towards modern fitted polos, while a warehouse team might prefer looser, breathable styles.

One client of ours—a growing Melbourne gym chain—switched from heavy cotton to a cotton/poly blend and noticed staff wearing their branded polos outside of work. Free advertising? Yes, please.

Expert tips for design placement, sizing, and colour matching

Once you’ve chosen your shirts and printing method, don’t skip the small stuff. It’s what makes a custom polo look pro instead of patchy.

Here are a few tips from our embroidery team:

• Keep it classic– Left chest is the most popular placement for logos. Centre back or sleeve adds subtle flair.
• Size smart– Bigger isn’t always better. Logos that are too large can warp or sit awkwardly.
• Colour match like a pro – Make sure your logo contrasts with the shirt colour (no black on navy, please).
• Send us the right design files – We prefer vector artwork files for the best results. Here’s the lowdownon how to get them to us.
• Test it first – If it’s a big order, do a sample print. It’s worth the extra day.

Quick reality check: polo shirt material can impact colour vibrancy. What looks great on paper might sink into certain knits—especially on dark fabrics. Always ask your printer for advice if you’re unsure.

Why high-quality custom polos are worth it

Custom polo shirts aren’t just walking adverts—they’re a first impression, a team uniform, and a long-term brand investment. Whether you aim to turn heads at your next event, build team pride, or launch your startup’s first merch range, the right polo makes all the difference.

And when it’s done right—with the perfect fit, print method, and expert embroidery—people remember.

Want help choosing the right polo for your brand or event? Explore our polo range or chat with our team about printing options—we’re happy to help you find your fit.

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