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By working with a screen printer that can do all over prints. Like these: http://www.t-shirtforums.com/screen-printing/t8891.html

It costs a lot of money to do a few (by few, I mean like 100), but when you're "big time", you run 1000's of t-shirts with the same design and you have almost guaranteed sales, so the costs are less and the risk is less.
 
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