Understanding Product Design and BurgerPrints' design standard
Overview
In print-on-demand, the quality of your final product starts with how your design file is prepared. A well-prepared design file helps ensure accurate print size, sharp details, and consistent results across different products and fulfillment facilities.
This article explains how BurgerPrints defines product design standards and how those standards affect printing outcomes. It is for users who create products and prepare design files and want to avoid common design issues such as blurry prints, incorrect sizing, or unexpected cropping.
After reading this article, you understand the core design principles BurgerPrints applies across products, how different design elements work together in production, and why following product templates is essential for achieving reliable print quality.
About BurgerPrints design standards
BurgerPrints applies a set of design standards across product types to ensure consistent print quality and reliable production results. These standards define how design files are prepared, processed, and printed within the BurgerPrints system.At a high level, BurgerPrints design standards are built on 4 core principles:
DPI (dots per inch) DPI defines the print resolution of a design file. It affects how sharp details, text, and edges appear on the final product.
Design dimensions Design dimensions define the exact pixel-based canvas size of a design file. Design files must be created using the required dimensions for each product to ensure correct scaling and placement.
Print area
The print area defines the maximum printable region on a product. Content placed outside this area may be cut off, resized, or not printed.
File format File format determines how a design file is processed by the system. Supported formats preserve transparency, color information, and print-ready quality throughout production.
In addition to these core principles, users must consider several supporting design factors when preparing design files:
Color profile (RGB, CMYK, Grayscale), which affects how colors are interpreted during printing
Bleed, which allows background artwork to extend beyond the trim line to prevent white edges
Safe zone, which protects important elements such as text and logos from being cut or distorted
Placement, which determines where artwork appears within the print area on the final product
These requirements vary by product type and printing method. Different products use different materials, shapes, and production techniques, which means their design standards are defined individually.
To account for these differences, BurgerPrints provides product templates for each product. A product template defines the required design dimensions, print area, safe zone, bleed, and placement for a specific product to ensure accurate printing results.
How product design works on BurgerPrints
On BurgerPrints, product design works as a system where multiple design elements are directly connected to determine how a design file is printed on the final product.
Because print-on-demand production does not involve manual adjustments, the system relies entirely on the accuracy of the design file provided. Design dimensions, DPI, print area, and placement do not function independently. This is why users must follow the basic design standards outlined above to achieve consistent print size and quality.
Print area and design dimensions
Each product on BurgerPrints has a defined print area, which represents the physical space available for printing on the product. Print area is typically defined in inches and is specified at the SKU level.
To achieve the maximum printable size for a product, the design file must be prepared using the correct design dimensions, calculated from the print area and DPI.
The relationship between these elements follows a simple formula:
Design dimension (in pixels) = Print area (in inches) × DPI
Example: If the target print area on a T-shirt is 14 × 16 inches, and the required DPI is 300, the design file should be prepared as follows:
14 × 300 = 4200 px
16 × 300 = 4800 px
In this case, the correct design dimensions are 4200 × 4800 px at 300 DPI.
This calculation is applied to almost all product designs and ensures that the design fills the intended print area accurately without being scaled up or down during production.
BurgerPrints adjusts the actual print file based on the relationship between design dimensions and print area:
Larger design dimensions scale down to fit the print area.
Smaller design dimensions print at their original size and do not scale up.
For the same product, print areas may vary by fulfillment location. Therefore, users must carefully check the corresponding print area specifications when selecting a fulfillment location before placing an order.
Why DPI matters in production
DPI plays a critical role in both print quality and print size accuracy. To understand the real impact of DPI, look at how the same design performs when printed at different resolutions. Even when the image size stays the same, changes in DPI make a noticeable difference in the final result.
A design prepared at 300 DPI produces a print that appears crisp, well-defined, and much closer to what you see on your screen. Lower DPI files, on the other hand, often lose clarity and fine details once they reach the production stage.
Using the DPI specified in the product template ensures that the design file prints at the correct size and maintains optimal sharpness and color consistency.
Placement, color, and layout considerations
Beyond print size and resolution, other design factors also influence how the final product looks:
Placement determines where the artwork appears within the print area. Incorrect placement can cause designs to look off-center or be partially cut.
Color profile (RGB, CMYK, or Grayscale) affects how colors are interpreted during printing. Some colors may appear different in print compared to on-screen previews.
Bleed and safe zone define how close artwork can be placed to the edges of the print area without risking trimming or distortion.
These elements are defined and visualized in the product template for each SKU. Following the template helps ensure that the artwork stays within safe boundaries and prints as intended.
For more detailed guidance on color handling, bleed, safe zones, and advanced layout considerations, refer to Understanding advanced design guidelines and best practices.
Design rules by product type
Design standards on BurgerPrints vary by product type because each group uses different materials, product structures, and printing technologies. As a result, design dimensions, print areas, and preparation requirements are defined separately for each product group.
Printed apparel
Printed apparel products include items such as T-shirts, sweatshirts, long sleeves, hoodies, and similar garments that use flat print areas. These products are currently produced using DTG and DTF printing technologies, depending on the SKU and fulfillment location.
Standard print area
For most printed apparel products, BurgerPrints defines a standard print area that applies to front and back prints:
T-shirt, sweatshirt, long sleeve:
Design dimensions: 4200 × 4800 px - 300 DPI
Hoodie, kid hoodie, cropped hoodie:
Design dimensions (front): 4200 × 3000 px - 300 DPI
Design dimensions (back): 4200 × 4800 px - 300 DPI
These design dimensions represent the standard print area and are suitable for most use cases.
Print area requirements may vary by fulfillment location and garment size. Users can find the exact print area dimensions for each SKU and location directly on the product page in the Catalog.
Note: When using Create product, pocket-specific print areas are not displayed. Users should create orders using CSV, Add custom product to access the correct print area.
Max print area
In addition to the standard print area, BurgerPrints supports max print areas for selected apparel products. Max print areas allow larger print coverage, but they are not available for all fulfillment locations.
For locations that support max print, the usable print area may be larger than the standard one. However, max print does not use a single fixed design dimension like the standard print area.
Instead, BurgerPrints provides recommended design dimensions for each supported location. These recommendations help users prepare design files that can reach the maximum printable area based on that specific fulfillment location’s production standards.Because of this:
Using a larger design dimension does not automatically guarantee that the design prints at the maximum size.
Users must always check the supported max print area and recommended design dimensions on the product page in the Catalog.
Max print area availability and recommended design dimensions are defined per fulfillment location and may vary between locations.
Sleeve print area
Sleeve prints are available for selected apparel SKUs and use narrower print areas compared to front and back prints. Sleeve print area dimensions vary by fulfillment location and product type.
Users must follow the sleeve print area dimensions displayed on the product page in the Catalog for each supported SKU.
Note: If users require design dimensions outside the standard or max print areas shown in the Catalog, they should contact BurgerPrints Support to confirm feasibility before uploading the design file.
Printing technologies: DTG vs DTF
BurgerPrints currently supports 2 printing technologies for printed apparel:
DTG (Direct-to-Garment) DTG printing applies ink directly onto the fabric. This method is best suited for detailed designs and photographic artwork. Design files should use smooth gradients and accurate color preparation.
DTF (Direct-to-Film) DTF printing transfers the design onto fabric using a film layer. This method offers strong color coverage and durability across a wider range of fabric types. Design files should account for solid color areas and edge clarity.
Each printing technology has specific design considerations. Users should review Understanding advanced design guidelines and best practices to prepare design files that match the selected printing method.
All Over Print apparel (AOP)
All Over Print (AOP) apparel products use dye-sublimation printing and are produced using a cut-and-sew process. Unlike printed apparel, AOP products do not use a single flat print area.
Designs for AOP products must cover the entire template area to avoid white edges, gaps, or misaligned seams.
Because AOP garments are assembled from multiple fabric panels, alignment between panels is approximate. Minor misalignment at seams is technically unavoidable and is not considered a defect. Small shifts may occur during cutting and sewing.
To achieve the best visual result, users should:
Extend background artwork fully to the bleed
Keep important elements inside the safe zone
Avoid placing critical design details directly on seam or fold lines
Design with tolerance in mind when matching artwork across panels
Drinkware
Drinkware products such as mugs, tumblers, and similar items typically use sublimation or UV printing on materials like ceramic, glass, or stainless steel. These products are commonly printed using a wrap-around layout.
Because artwork wraps around a curved surface, correct placement is essential to achieve even color transitions and balanced layouts.
When designing for drinkware products, users should:
Keep important elements inside the defined safe zone
Follow placement guides shown in the product template
Avoid placing critical artwork directly on wrap transition areas
Incorrect placement may result in visible seams, uneven color transitions, or partial cropping. Small variations in wrap alignment may occur due to the curved surface and printing process.Example: Mug Template
Mugs can be printed across the entire surface using a full-wrap design. In addition, the product template defines two placement areas to help control artwork visibility:
Left placement: the side visible when the mug is held with the right hand
Right placement: the side visible when the mug is held with the left hand
These placement areas are useful when users want to:
Place text or logos on a specific viewing side
Create mirrored or left-right symmetrical designs
Maintain a balanced layout without using a full-background design
For full-wrap designs, users only need to cover the entire template area and do not need to apply placement markers.
Home decor and personal accessories
Home decor and personal accessory products include items such as ornaments, posters, pillows, and similar products. These items have fixed physical shapes and often involve cutting, pressing, or sewing during production.
Designs for these products must follow bleed, border, and safe area guidelines to prevent white edges, uneven borders, or important elements being trimmed or distorted. Users must always follow the product-specific template provided in the Catalog.In general, these products:
Use a single fixed print area
Do not require mirrored placement like drinkware products
May include placement indicators to avoid seams, holes, or structural cutouts
Require all important elements (text, logos, key graphics) to be placed inside the safe zone
Example: Ornament Template
An ornament template typically includes:
Safe area: the area inside the dashed lines. Place all essential elements here, as this zone is protected from trimming.
Not safe area: the area between the safe area and the trim line. This area may be trimmed slightly, do not place important content here.
Bleed: background elements must extend beyond the trim line to prevent white edges after cutting.
Hanging hole: the hole at the top of the ornament. Avoid placing text or key details near this area.
Minimum line thickness requirement
When creating design files, users must ensure that all lines, cutouts, and structural details have a minimum thickness of 2 mm.Very thin elements may not reproduce correctly during production and can cause quality issues such as:
Lines appearing broken or blurry when printed on apparel
Small details disappearing after printing
Structural parts breaking or snapping during cutting on hard goods (for example: ornaments, acrylic items)
This requirement is especially important for:
Hanging holes or cutout areas
Outlines, borders, and fine strokes
Small text converted to shapes
Designs used for laser-cut or press-cut products
Example: In the ornament below, the hanging hole breaks during production because the surrounding line is too thin and does not meet the minimum thickness requirement.
We recommend reviewing your design at 100% scale and increasing line thickness where needed before uploading the design file.
Tips and Best Practices
Following these best practices helps ensure consistent print quality and reduces production errors:
Always start with the product template: Design directly on the official template to ensure correct design dimensions, placement, and safe zones.
Use the required DPI for each product: Matching the DPI specified in the template helps maintain sharp details and accurate print size.
Design at full size from the beginning: Avoid scaling up small images. Enlarging low-resolution artwork often results in pixelation and loss of detail.
Keep important elements inside the safe zone: Text, logos, and key graphics should stay within the safe zone to prevent trimming or distortion.
Be mindful of color differences: Colors may appear different in print compared to on-screen previews. Avoid overly bright or oversaturated colors and ensure sufficient contrast.
Review the mockup preview before publishing: Use the Dashboard mockup preview to check alignment, placement, and overall appearance before saving the product.
Common issues and how to fix them
Below are common design-related issues and how to address them:
Blurry or pixelated prints
Cause: The design file uses low DPI or was created at smaller design dimensions and scaled up.
Fix: Recreate the design file using the required design dimensions and DPI shown in the product template.
Incorrect print size on the product
Cause: The design dimensions do not match the required print area for the SKU.
Fix: Check the print area and design dimensions on the product page or template and update the design file accordingly.
Important elements are cut off
Cause: Artwork is placed outside the safe zone or too close to the edge.Fix: Move all essential elements (text, logos, faces) inside the safe zone defined in the template.
Colors look different from the design file
Cause: Differences between screen display (RGB) and print output, or overly saturated colors.
Fix: Adjust color levels, avoid extreme brightness, and follow color guidance outlined in the advanced design guidelines.
Design does not align correctly on AOP or wrap-around products
Cause: Artwork is placed too close to seams, folds, or wrap transition areas.
Fix: Design with tolerance in mind, extend backgrounds to bleed, and avoid placing critical elements on seam or transition lines.
Frequently Asked Questions
Why do printed colors look different from my screen? Screen displays use RGB light, while printing uses CMYK-based processes. Some bright or oversaturated colors cannot reproduce exactly. Increase contrast, avoid overly bright tones, and check your design under neutral lighting for more accurate results.
What is the recommended file size? Use the required pixel dimensions provided in the product template and keep your file at 300 DPI. File size may vary, but keeping your file size reasonably small (for example, under 50 MB) helps ensure smooth upload and processing.
Do you support vector files? Yes. You can upload vector formats if they are exported correctly (for example: high-resolution PNG from AI/PSD, or supported vector formats depending on the system). Make sure all text is outlined and effects are flattened before exporting.
How should I use the product template? Open the template in your design software, place your artwork inside the print area, keep important elements within the safe zone, and export your final file using the required size and DPI.
Related articles
Understanding advanced design guidelines and best practices
How to download design templates from the product catalog
Understanding the BurgerPrints Product Catalog
Which positions on the product does BurgerPrints support printing?
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