The complete guide to custom jackets & outerwear.

Why custom jackets work

A custom jacket is the most premium thing you can put a brand on. It's worn all season — on the sideline, the job site, the trade-show floor, the walk from the car — and it reads as real gear people keep, not a giveaway they toss. Outfit a team in a matching shell and the group instantly looks organized and legitimate, which is exactly why companies, clubs, and crews invest in branded outerwear.

Three choices shape the result: the fabric and layer, the decoration method (a coated waterproof shell decorates very differently than a cotton-blend coach's jacket), and the style and fit. Get them right and you have a jacket that suits the weather, holds a clean logo, and lasts. The sections below walk through each — and every jacket is decorated in-house here in Coatesville, PA.

Jacket types & fabrics: fleece, soft shell, puffer, windbreaker & rain

Start with what the jacket has to do. Fleece is a warm, soft mid-layer; a windbreaker is a lightweight shell that blocks wind; a soft shell adds structure plus wind and light-rain resistance; a puffer traps the most warmth for cold; and a rain shell is a sealed, waterproof outer layer. Warmth and weather protection usually trade off against packability and price.

• Fleece is a napped polyester knit that's soft, breathable, and warm for its weight — the easiest jacket to decorate, but on its own it doesn't block wind or rain.
• Windbreaker is a lightweight woven nylon or polyester shell that stops wind and sheds a light drizzle, then packs down small. Minimal warmth, maximum portability.
• Soft shell bonds a durable water-repellent (DWR) face fabric to a wind-blocking, breathable membrane and a soft fleece backing — wind- and water-resistant with a structured, retail feel.
• Puffer / insulated quilts a shell around down or synthetic fill for the most warmth per ounce; many pack into their own pocket.
• Rain shell uses a coated or laminated waterproof fabric with sealed seams — the pick for genuine wet weather.

The fabric also decides how the jacket decorates — a soft cotton-blend coach's jacket takes ink like a tee, while a coated nylon shell needs a heat-pressed transfer. Browse fleece jackets, soft shells, puffer jackets, windbreakers, and rain jackets.

How custom jackets are decorated: screen print, DTF & dye-sublimation

Two methods cover almost every jacket: screen printing for bulk runs of a bold logo on flat cotton-blend panels, and DTF for full-color art or, critically, for coated and nylon shells. The fabric drives the choice — a soft coach's jacket prints like a tee, while a water-resistant shell needs a heat-pressed transfer applied at the right temperature.

Screen printing lays durable, opaque ink and is the most economical route for a bold logo across a big roster — best per-piece pricing starts around 24 pieces. It's happiest on flat, absorbent cotton-blend panels like a fleece or a coach's jacket back; it doesn't suit slick, coated, or waterproof shells.

DTF (direct-to-film) prints full color with no minimum and is the safe choice for outerwear. Coated and heat-sensitive nylon shells can scorch at screen-print cure temperatures, so we press DTF transfers at a lower temperature; the film bonds cleanly to synthetic fibers without dye migration, typically holding 50–60 washes with minimal cracking.

Dye-sublimation turns dye into a gas that bonds permanently inside polyester fiber, so it never cracks or peels. It's for all-over designs on light-colored shells that are at least 65% polyester — it won't bond to cotton or to dark fabrics.

You'll also hear about direct-to-garment (DTG), which sprays ink into cotton fibers — it's built for flat, high-cotton tees, not the coated shells and quilted panels most jackets use. We don't run DTG; for full-color detail on outerwear we use DTF, which presses onto fleece, nylon, and cotton blends alike. Not sure which method fits your jacket? Send us the specific blank and your artwork and we'll recommend the best one.

Logo placement & sizing

The standard jacket logo is a left-chest mark about 3.5–4 inches wide on a flat panel, kept clear of the zipper, pockets, and seams. A full-back logo across the yoke — roughly 10–12 inches wide — makes a bold team statement, and sleeves or the nape work well for a second mark.

• Left chest: the primary spot — about 3.5–4 in wide, on a flat chest panel away from the zipper and pockets.
• Full back: a large statement mark, roughly 10–12 in wide, across the upper-back yoke.
• Sleeve: a small logo or wordmark, about 2–3 in, down the upper arm.
• Nape / collar back: a small tag logo just below the collar seam.

On coated, waterproof, and nylon shells we match both the method and the press heat to the fabric, and keep art on flat panels so it presses evenly. Zippers, pocket flaps, and seams are best avoided.

Choosing the right jacket for your use case

Match the jacket to who's wearing it and where. Staff and corporate programs favor a clean soft shell or lightweight shell that layers over a polo; sideline and team crews lean on fleece and snap-front coach's jackets; outdoor and field work wants wind and water resistance; and cold-weather crews need insulation.

Pick by fabric & layer

A warm, easy-to-print Harriton M990 Full-Zip Fleece is the value mid-layer for staff and teams. For wind and light rain with a retail feel, the Team 365 Leader Soft Shell is the corporate go-to, while the unlined CORE365 Techno Lite is a clean, year-round lightweight shell. Need packable wind protection? The Independent Trading windbreaker and the Champion packable anorak both stuff down small.

Pick by style & fit

For a casual, team-spirited look, a snap-front coach's jacket like the Augusta 3100 gives a flat back panel that's ideal for a big logo. Once you've settled on the look, shop by fit: men's, women's, or an easy-to-order unisex cut for mixed groups where you want one style across everyone.

Ordering, turnaround & cost

Pricing depends on the blank, quantity, number of print colors, and method — larger orders lower the per-piece cost, and setup is always included, with no surprise fees. Standard turnaround is about 6 business days after art approval, and many items ship in 1–2 days; rush service is often available.

You can also supply your own jackets — just check compatibility with us first, since coatings, linings, and fabric type affect whether screen printing or DTF is the better fit. Request a free quote for exact numbers on your design and quantity.