build a gang sheet
February 8, 2025

Top Mistakes to Avoid When Building a Gang Sheet

Building a gang sheet is one of the most effective ways to maximize printing efficiency, reduce material waste, and save costs. However, many designers and print businesses make common mistakes that can lead to poor-quality prints, misalignment, and unnecessary expenses. If you want to ensure a seamless and professional output, you need to know what pitfalls to avoid.

In this guide, we will highlight the top mistakes to steer clear of when you build a gang sheet, ensuring you get the best results every time.

1. Not Using the Right Software

One of the biggest mistakes is using the wrong software to build a gang sheet. Many people attempt to arrange their designs manually in basic programs like Microsoft Word or Paint, which lack the necessary alignment tools. Instead, professional software like Adobe Photoshop, CorelDRAW, or Affinity Designer should be used to ensure precision and accuracy.

Solution:

  • Use professional design software that allows proper alignment and scaling.
  • Look for tools with smart grid and guide features to optimize layout.

2. Ignoring Proper Spacing Between Designs

Failing to leave enough space between designs can lead to overlapping, cutting errors, or ink smudging. This is especially important for Direct-to-Film (DTF) and screen printing, where cutting inaccuracies can ruin multiple designs at once.

Solution:

  • Maintain at least 0.25 inches of spacing between each design.
  • Use guidelines to check for even spacing before finalizing your gang sheet.

3. Not Considering Print and Cut Margins

Every printing method has different margin requirements. If you don’t account for these margins when you build a gang sheet, your prints may get cut off or misaligned.

Solution:

  • Research the margin requirements of your specific printer or transfer method.
  • Add bleed margins if necessary to avoid unintended cropping.

4. Using Low-Resolution Images

A major error in gang sheet preparation is using low-quality or pixelated images. This results in blurry or distorted prints, which can make designs look unprofessional and unappealing.

Solution:

  • Ensure all images are at least 300 DPI (dots per inch) for high-quality output.
  • Avoid stretching smaller images beyond their resolution capacity.

5. Failing to Convert Fonts to Outlines

If you use custom fonts in your design and don’t convert them to outlines before saving, they may not render correctly on another device. This can cause font substitutions, leading to design distortions.

Solution:

  • Convert all text to outlines or curves before finalizing the gang sheet.
  • Save files in universally compatible formats like PDF or EPS.

6. Overcrowding the Sheet

Trying to fit too many designs onto a single sheet might seem like a great way to maximize material usage, but it can result in poor print quality and cutting errors.

Solution:

  • Balance efficiency with quality by ensuring each design has enough space.
  • Test different layouts to find the best arrangement for optimal print clarity.

7. Forgetting to Mirror Images for Heat Transfers

For heat transfer printing methods such as sublimation or DTF, forgetting to mirror your designs before printing can ruin an entire batch.

Solution:

  • Always double-check if mirroring is needed for your specific printing method.
  • Use software settings to automate the mirroring process if available.

8. Not Testing Before Full Production

Skipping the test print stage can lead to costly errors and wasted materials. Without a trial run, you may overlook alignment issues, color mismatches, or other print defects.

Solution:

  • Always print a sample before running a full batch.
  • Make necessary adjustments based on the test print feedback.

9. Using the Wrong File Format

Submitting files in incompatible formats can cause printing errors or design distortions. Some printers may not support certain file types, leading to unexpected issues.

Solution:

  • Save your gang sheet in high-quality formats such as PDF, PNG, or TIFF.
  • Check with your print provider for preferred file specifications.

10. Neglecting Color Mode Settings

If your designs are not set to the correct color mode, your prints may come out looking completely different from what you expected.

Solution:

  • Use CMYK mode for print designs to ensure color accuracy.
  • Calibrate your monitor and printer settings for consistent results.

Conclusion

When you build a gang sheet, avoiding these common mistakes can save you time, money, and frustration. By using the right software, ensuring proper spacing, and following best practices, you can create a high-quality gang sheet that optimizes your printing process. Always test before full production and double-check every detail to ensure a smooth and professional outcome.

Have you made any of these mistakes before? Let us know in the comments and share your best tips for creating the perfect gang sheet!