So far I've only had this happen once and I just replaced the shirt, but I still had the screen and it had only been worn once. I have had 2 gildan's that I've caught the seam coming apart or already apart before I printed them. I live in a small town so the customer service angle is most important here. If I didn't have the screen still made then I'd likely explain that it couldn't be remade but yes I'd try and sew it up for them at no charge.

 

Not sure who your supplier is, but the ones we deal with will replace garments that are defective. We press all of our shirts and always make extra transfers when we get an order for situations like this (or if we mess up when we are pressing - but that never happens). This makes pressing a new shirt for the client really easy and we keep the customer happy. We had customers that are so surprised that we will replace a defective garment that they end up coming back for more stuff. Even if your client damaged the garment, it pays to take a small loss and just replace it. We are very strong on customer service and our customers really appreciate that.

 

We get our shirts from Sanmar, and they do replace shirts that we get that are defective, but I had one order where like 4 out of 12 shirts came back. That was a couple of years ago, and the percentage of shirts we have come back are small, but it's 99% armpit seams.

We had a customer two weeks ago that came in with this issue and told us the shirt had never been worn. Of course, it reeked of fabric softener and when my manager pointed that out, the guy was like yeah, it was only worn once and washed. He purchased it as a work shirt, and only bought one.

It's just a pain in the neck dealing with customers that lie to you. lol I completely understand the customer service aspect, which is why until now we have always repaired the seams or reprinted. But, it is time consuming replacing/repairing a shirt that someone got weeks before.