Print on Demand Underwear: How to Start and Succeed in 2025

In recent years, the print on demand industry has expanded far beyond T-shirts and mugs, opening the door for more unique niche products and custom underwear is quickly emerging as a surprising yet highly profitable contender. Print on demand underwear is a growing trend in the custom apparel industry. With POD platforms like PeaPrint, you can easily design and sell your own underwear. With the increasing demand for personalized underwear, entering the print-on-demand underwear market may be a good choice.

Understanding Print on Demand Underwear

In traditional apparel sales, you must invest in inventory to establish yourself in the market. However, with custom apparel, this limitation is eliminated, especially with print-on-demand lingerie. You can create and sell custom lingerie without inventory. Your unique designs can help you reach the right customers directly. Here's what you need to know.

Why Print on Demand Underwear Is a Growing Opportunity

The global underwear industry is growing steadily, driven by rising demand for both comfort and personalization. According to a report by Grand View Research, the global underwear market was valued at USD 107.9 billion in 2023 and is projected to reach USD 146.6 billion by 2030, registering a compound annual growth rate (CAGR) of 4.4%.

Print on Demand enables small businesses and independent designers to tap into this market without the heavy costs of bulk manufacturing. Custom underwear also offers strong repeat-purchase potential. A Statista survey shows that underwear is among the highest repeat-purchase apparel categories, meaning loyal customers often reorder if they love the fit and style. Add seasonal opportunities, like Valentine’s Day, anniversaries, and holiday gifting and POD underwear becomes a sustainable business niche with year-round sales potential.

Common Techniques for Producing POD Underwear

When creating custom underwear through Print on Demand, the choice of printing or embellishment method plays a big role in the final product’s comfort, durability, and appearance. Below are the most common techniques used in the industry:

Direct-to-Garment (DTG) Printing:

DTG uses specialized inkjet printers to apply water-based textile inks directly to the fabric.

Best For: Cotton or cotton-rich blends

Advantages: High detail, unlimited colors, soft feel

Considerations: Works less effectively on polyester or high-stretch fabrics

Sublimation Printing

Sublimation uses heat to turn dye into gas, bonding it directly with polyester fibers for vibrant, fade-resistant prints.

Best For: Polyester, spandex blends

Advantages: No cracking or peeling, perfect for full-color designs

Considerations: Not suitable for natural fabrics like cotton

All-Over Printing (AOP)

AOP allows designs to cover the entire garment from edge to edge, creating a seamless, fully customized look. This is typically achieved through sublimation on cut-and-sew pieces.

Best For: Bold patterns, graphic-heavy designs, novelty underwear

Advantages: Maximum creative freedom, unique premium look

Considerations: Usually higher cost and longer production time compared to standard printing

Starting Your Print on Demand Underwear Business

Careful planning is required before starting any business, whether it is choosing a niche or selecting a platform and suppliers. Some of these details will affect your subsequent development.

Choosing Your Niche in Custom Underwear

All successful businesses don't try to cater to everyone; instead, they find a niche and focus on a specific audience or style. For example, while everyone is competing in DTG and sublimation printing, entering the all-over printing (AOP) underwear market can help you break through by reducing competition and increasing your room for growth.

All-over printing technology, unlike other limited printing technologies, allows your design to cover the entire underwear piece. This is exactly what PeaPrint excels at. We offer advanced all-over printing technology, delivering higher-quality printing to create unique products in the custom underwear market.

Focusing on a unique niche, such as AOP or other visually striking concepts, allows your brand to attract attention in a competitive market and build a loyal customer base that resonates with your style.

Best Platforms for Selling Print on Demand Underwear

Your choice of selling platform will directly impact your brand’s visibility and profitability. If you want complete control over your store’s design, pricing, and branding, building your own online shop with an e-commerce platform like Shopify or WooCommerce is ideal. If you prefer tapping into an existing customer base, marketplaces like Etsy or Amazon provide instant access to millions of potential buyers. Some entrepreneurs use a hybrid approach, maintaining their own branded store while also selling select designs on marketplaces to reach a wider audience.

Finding the Right POD Supplier

A reliable POD supplier is undoubtedly the backbone of your print-on-demand lingerie business. Look for a supplier that specializes in print-on-demand apparel, such as PeaPrint. We offer seamless integration with your store and a variety of printing methods.

You can compare and select the right POD supplier based on the following criteria:

Product Quality: Read reviews and order samples to verify the fabric quality, accurate printing, and consistent sizing.

Customization: Ensure the service allows you to easily create custom designs.

Fulfillment and Shipping: This is a critical aspect that directly impacts customer satisfaction. Ensure production and delivery times meet your customers' expectations.

Price: Compare prices across suppliers and select the one that offers the best value to maintain your profit margin.

Designing Your Underwear Line

Designing your custom underwear line is where creativity meets market demand. The goal is to create designs that resonate with your niche while maintaining wearability, comfort, and brand identity.

Which design of themes are more effective?

Collaborating with Artists and Designers

Partnering with skilled illustrators, pattern designers, or typography experts can elevate your underwear line’s appeal. Even if you’re using stock elements, working with creatives ensures originality and helps your designs stand apart from generic options. Collaboration can be one-off (per design) or ongoing, allowing you to maintain a consistent style while tapping into different artistic visions.

You can find some excellent designers through freelancing platforms such as Fiverr or Upwork and establish long-term cooperative relationships with them. You can also use PeaPrint's easy-to-use design tools to help you design and sell with no upfront costs.

Ensuring Design Quality and Comfort

The essence of underwear lies in its functionality, not just its appearance. Therefore, don't sacrifice design quality and comfort for appearance. Opt for materials that are durable and can withstand daily wear. Ensure that all designs are adaptable to different body types; this can also expand your product's customer base. Before releasing your product to your store, test samples to ensure customer satisfaction. High-quality products lead to better word-of-mouth, increased repeat business, and fewer returns.

Fabrics for Print on Demand Underwear

The choice of fabric plays a critical role in the comfort, durability, and appeal of your custom underwear. Each material comes with its own benefits and ideal use cases, so understanding the differences will help you make better product decisions.

Cotton

Pros:

Soft and breathable, ideal for everyday wear

Hypoallergenic and gentle on the skin

Good moisture absorption

Cons：

Shrinks easily if not pre-shrunk

Less stretch compared to synthetic fabrics

Colors may fade over time

Why Choose:

Cotton's natural properties make it breathable and soft, especially for sensitive areas.

Polyester

Pros:

Durable and resistant to shrinking

Holds colors well—great for vibrant prints

Quick-drying and lightweight

Cons:

Less breathable than natural fibers

Can retain odors if not treated

May feel less soft compared to cotton

Why Choose:

Best for bright, all-over prints (AOP) and activewear-inspired underwear.

Spandex/Elastane

Pros:

Excellent stretch and recovery

Enhances fit and comfort

Lightweight and smooth texture

Cons:

Usually blended with other fabrics

Can lose elasticity over time if poorly cared for

Why Choose:

Perfect for adding flexibility to cotton or polyester blends, improving fit for active and fashion-forward designs.

Nylon

Pros:

Smooth and silky feel

High durability and abrasion resistance

Quick-drying

Cons:

Not as breathable as cotton or bamboo

Can yellow with age

May cause static buildup

Why Choose:

Ideal for sleek, modern underwear styles and sports-inspired designs.

Bamboo Fabric

Pros:

Soft, breathable, and naturally antibacterial

Eco-friendly and biodegradable

Excellent moisture-wicking

Cons:

Can be more expensive

Requires gentle washing to maintain softness

Why Choose:

A great choice for sustainable underwear collections targeting eco-conscious customers.

Microfiber

Pros:

Ultra-soft and smooth texture

Lightweight and breathable

Resists wrinkles and maintains shape

Cons:

Less natural feel compared to cotton or bamboo

Can trap heat in very hot climates

Why Choose:

Ideal for premium, luxury-feel underwear that prioritizes comfort and a sleek appearance.

Modal

Pros:

Extremely soft and silky

Excellent moisture absorption

Drapes well without clinging

Cons:

Slightly more delicate in washing

Can be pricier than cotton

Why Choose:

Perfect for high-end, comfort-focused underwear collections.

Tencel (Lyocell)

Pros:

Soft, breathable, and eco-friendly

Naturally resistant to bacteria

Durable and strong even when wet

Cons:

More expensive than common fabrics

Limited availability in some markets

Why Choose:

Ideal for sustainable luxury underwear targeting eco-conscious fashion buyers.

Cotton-Polyester Blend

Pros:

Combines softness of cotton with durability of polyester

Wrinkle-resistant and shrink-resistant

Good balance of comfort and print quality

Cons:

Less breathable than pure cotton

May pill over time

Why Choose:

A versatile, cost-effective option that works well for both comfort and vivid prints.

Branding and Customization Options

Building a brand is the most effective way to liberate yourself from fierce competition. It also allows you to earn higher profit margins than your competitors. Therefore, building a strong brand image and attracting more customers is crucial for custom underwear.

Creating Unique Brand Identity

Focus on elements that reflect your brand style. Consider color themes and patterns that reflect your brand message. Create a simple, eye-catching logo that you can place on underwear and packaging. This will help promote your brand in the long run and help more and more people know about your brand.

Logo Placement

Discreet logo prints on the waistband, inner labels, or side seams create a professional and polished look without overwhelming the design.

Beautiful packaging can significantly enhance your customers' impression of your brand, so consider customizing packaging that's consistent and features your branding.

By investing time in these areas, you can build a brand that customers recognize and trust.

Marketing Your Custom Underwear Brand

Opening a store successfully doesn’t guarantee success. Customers won’t spend time learning about an unknown brand. You need to reach your customers through a variety of means, including brand storytelling, audience research, and social media marketing.

Building a Brand Narrative

Best-in-class brands create an emotional connection with their customers through their brand story. Your brand narrative is more than just a slogan—it’s the story that connects your underwear to your customers’ values and lifestyle. A strong narrative should communicate your mission (comfort, sustainability, humor, inclusivity, etc.) and set you apart from generic competitors.

Know Your Target Audience

Understanding who you’re selling to determines everything from product design to advertising platforms. Are you targeting young adults seeking trendy and bold prints, athletes needing performance underwear, or couples looking for matching sets? Analyze demographics, buying behavior, and style preferences. Use surveys, social media polls, and customer feedback to refine your ideal buyer persona and ensure every decision appeals directly to them.

Social Media Marketing

Social media is one of the most cost-effective ways to grow a POD underwear brand.

Platforms like Instagram, TikTok, and Pinterest are great for showcasing your unique designs. Try sharing compelling photos and videos to promote your products.

Also, consider collaborating with influencers to promote your brand and products. Choose influencers whose audience matches your target market and whose style aligns with your brand image. For example, fitness influencers could promote your performance underwear. Offer free samples, affiliate partnerships, or commission-based promotions to encourage authentic endorsements.

Seasonal Marketing Opportunities

Underwear sales can surge during specific seasons and events. For example, Valentine’s Day, Christmas and the holidays, back-to-school, and summer—plan your design releases and advertising campaigns around these seasonal peaks to capitalize on consumer buying patterns.。

Advertising strategy

If you strategically place paid ads, you can accelerate brand development. Through ads, you can quickly gain exposure and test which of your products meet market demand, so that you can make subsequent product selections.

Meta Ads (Facebook/Instagram): Use detailed targeting to reach niche demographics.

Google Ads: Capture high-intent searches like “funny custom underwear” or “eco-friendly boxers.”

TikTok Ads: Run creative short-form campaigns for brand awareness.

Start with small budgets, test different creatives and audiences, and scale up what works best. Retargeting ads are especially effective for reminding visitors who didn’t purchase to come back and complete their order.

Focus on Customer Satisfaction

In addition to attractive products, providing excellent customer service is crucial for building a loyal customer base. For a high-repurchase product like underwear, retaining one customer means retaining future orders. In terms of customer service, special attention should be paid to handling returns, exchanges, and customer complaints.

• You should establish a clear and explicit return and exchange policy and make it publicly available in your store.
• When processing returns, ensure that customers receive refunds as quickly as possible. Timely returns and refunds build customer trust and encourage future purchases.
• Handle customer complaints appropriately and appease customers to the best of your ability.
• Keep up to date with product reviews to understand customer feedback.

FAQs

What is Print on Demand underwear?

Print on Demand underwear allows you to sell custom-designed underwear without holding inventory. Each piece is printed and shipped only when a customer places an order, reducing upfront costs and risks.

How do I ensure print quality on underwear?

Choosing the right printing method for your fabric is key—DTG works best on cotton, while sublimation is preferred for polyester blends. Always order samples before launching to check color accuracy and print durability.

How long does it take to fulfill a POD underwear order?

Order fulfillment time varies by supplier, but PeaPrint typically takes 3 to 5 business days. Shipping time is additional and depends on the destination and shipping method selected.

Can I sell Print on Demand underwear internationally?

Yes, with PeaPrint's robust global shipping service, you can sell POD underwear worldwide to increase your sales. However, please be sure to consider shipping costs and delivery times when targeting international customers.

Conclusion

Starting a Print on Demand underwear business offers an exciting opportunity to combine creativity with entrepreneurship. By choosing the right niche—such as all-over printing designs—selecting quality fabrics, partnering with reliable suppliers, and crafting a strong brand identity, you can build a unique underwear line that stands out in a competitive market.