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How We Produce Custom AOP Pillowcases from Start to Finish — and Why Brands Love Them
Custom products that blend style, quality, and personal touch are more popular than ever — and all-over print (AOP) pillowcases have quickly become a favorite. Whether you’re an individual looking to refresh your home decor or a brand wanting to offer a standout product, AOP pillowcases offer a unique way to make a statement.
In this post, we’ll take you behind the scenes to show exactly how we make each pillowcase from start to finish — plus why so many brands are adding them to their collections.
What Is an AOP Pillowcase — and Why It Matters
AOP stands for “all-over print”, meaning the entire fabric surface is covered in your design — no small logos or patches, but a bold, seamless artwork that wraps from edge to edge. This creates a vibrant, eye-catching product that feels truly custom-made.
Our pillowcases are perfect for anyone who wants to bring a personal or branded design to life — with vivid colors and a professional finish.
The Step-by-Step Process Behind Our AOP Pillowcases
1. Online Customization & Automated File Preparation
It all starts with our online customizer. When you upload your design and place an order, the system automatically prepares all the necessary print files, arranged perfectly for production. This means your design is split into cutting patterns with clear cut lines and registration marks — all ready for print, without any extra manual work.
2. Printing on High-Quality Fabric
Depending on your fabric choice, we print using two main methods:
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Pigment printing for natural fibers like cotton, which results in soft, breathable pillowcases with rich, lasting colors.
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Sublimation printing for polyester fabrics, where the ink becomes part of the fiber, delivering vibrant and durable prints. Each print is carefully done to ensure your design’s colors and details come out exactly as intended.
3. Variety of Sizes and Fabrics
To fit different needs, we offer three popular pillowcase sizes:
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40 x 40 cm
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40 x 65 cm
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50 x 50 cm
You can also choose from five different fabric options, including favorites like:
Each fabric offers a different texture and feel, so you can pick the one that best suits your project — whether you want something soft and natural or durable and structured.
4. Precise Automatic Cutting & Expert Sewing
After printing, the fabric is sent to our automatic cutting machines, which follow the cut lines in your design files perfectly to reduce waste.
Our sewing team then assembles the pillowcases using hidden zipper closures — a sleek, practical feature that makes washing easy and keeps the look clean and polished.
5. Final Quality Control & Thoughtful Packaging
Every pillowcase undergoes a detailed quality check to ensure colors are vibrant, seams are secure, and zippers work smoothly. Once approved, we package each item carefully, ready to ship directly to you or your customers.
Why Brands Choose Our Custom AOP Pillowcases
Total Design Freedom
With AOP printing, your entire pillowcase becomes a canvas — perfect for bold patterns, limited editions, or artist collaborations that make a statement.
Low Minimum Orders & Easy Dropshipping
Our microfactory setup and dropshipping options mean you can order as few as one pillowcase or small batches. This flexibility is great for testing new designs or offering exclusive products without risk.
Fast Turnaround & Local Production
All production happens under one roof, so orders are completed quickly. Local production also means better communication and control throughout the process.
Commitment to Sustainability
We prioritize eco-friendly materials like GOTS-certified organic cotton and OEKO-TEX® certified inks. Producing on demand helps reduce waste and overstock — a win for brands and customers who care about the planet.
Ready to Create Your Custom AOP Pillowcases?
Whether you want to personalize your home or expand your brand’s product range, our custom all-over print pillowcases combine creativity, quality, and sustainability.
At Caspar Create, we don’t just make pillowcases — we craft opportunities for brands and individuals to stand out with style and substance.