You’ve got a lovely, clean vector design. Now imagine it on the kind of T-shirt you’d rummage through a vintage shop to find. Cracked ink, worn lettering, bags of character. It looks like it’s survived twenty years of gigs, questionable nights out and the occasional collision with a burger. You only finished the artwork this morning.
That’s the finish we’re going for. In this tutorial, I’ll show you how to use my plastisol textures in Illustrator to turn clean artwork into a design that feels aged, worn and worth keeping. A few simple steps, plenty of room to experiment, and no need to sacrifice your favourite T-shirt.
This walkthrough uses my paid plastisol texture kit for Illustrator. You’ll apply vector cracks and missing patches of ink to your artwork, recreating the worn finish of an old screen-printed design.
Jump to the steps · Watch the video
The first screenshot shows the artwork and texture before applying the effect. The second shows the finished result.
What do you need before you start?
You’ll need Adobe Illustrator on desktop, my plastisol texture kit for Illustrator and some vector artwork to try it on. Bold lettering and chunky illustrations give the cracks plenty of room to show themselves.
Open a working copy of the kit so you can experiment without changing the original. There are 20 texture layers to explore, from lighter cracking to a more battered finish. Keep a separate copy of your clean artwork too.
I made the original textures from real plastisol ink printed onto T-shirts, then stretched and washed the prints to create the cracks. You can read how I made them here. Your computer gets to skip the washing machine.
Working in Photoshop instead? Follow my Photoshop plastisol tutorial, which uses the separate Photoshop kit.
Watch me create the aged plastisol look in this quick video
Some of the tutorial screenshots are taken from this video, so they’re a little rough around the edges. It explains everything quickly and simply, but I’ll still walk you through the process below.
1. Choose a plastisol texture in Illustrator
Open the kit in Illustrator and have a look through the 20 texture layers. Switch their visibility on and off to see the different cracking patterns. Some give you finer cracks; others look considerably more battered. Pick one you’d like to try with your artwork.
Keep your chosen texture layer visible and unlocked. Hide or lock the other texture layers so you don’t accidentally select them while you work.
2. Paste in your artwork and send it to the back
- Make sure your chosen texture layer is active.
- Paste in your artwork.
- Go to Object → Arrange → Send to Back so your design sits behind the texture.
- Move and resize your artwork until you’re happy with how the two line up.
- Select both your artwork and the chosen texture, leaving unrelated objects unselected. Use the Layers panel to check what you’ve selected.
3. Make a clipping mask
- With your artwork and the texture selected, right-click and choose Make Clipping Mask.
- You should now see the plastisol texture applied to your design.
- If Illustrator reports an error or the artwork disappears, check your selection and object order before continuing.
You might still have extra shapes around the artwork. We’ll tidy those up next.
The screenshot below shows the artwork with the texture paths selected. The coloured outlines help you see the paths; they aren’t part of the finished design.
4. Tidy up with Pathfinder
Save a separate copy before using Crop. This operation changes the paths, so keep a version you can return to if you want to adjust the earlier setup.
- Keep your clipped artwork selected.
- Open Window → Pathfinder.
- Click Crop in the Pathfinder panel to remove the extra shapes outside the clipping boundary.
- Deselect everything so you can see the finished cracked plastisol effect without the selection outlines.
Here’s the finished effect after tidying up and deselecting the artwork.
5. Try another texture
You’ve got your first result. Now try the same artwork with a different texture and see which you prefer.
- Start again with a fresh copy of your original artwork.
- Choose another texture layer.
- Repeat the steps: paste, send to the back, make a clipping mask and crop.
- Compare the results at the size you intend to use the design.
The most battered option won’t necessarily be the best. Give the finer cracks a go as well. You’re after a bit of character, and how much is entirely up to you.
Here are a few more examples showing how the textures work with different lettering and shapes.
6. Save your finished artwork
- Save your finished design as a new Illustrator (.ai) file, keeping your original artwork and texture kit separate.
- Keep this Illustrator file as your editable master, alongside your saved copy from before cropping.
- Export a copy in the format you need for your project. If you’re getting it printed, ask your printer which format they prefer.
Saving as an Illustrator file keeps the remaining vector paths editable. It doesn’t restore parts you’ve already removed with Crop.
Your vector artwork stays sharp when you resize it. The cracks scale with it, though, so check that finer details will reproduce at your intended print size. Any placed bitmap images still depend on their resolution.
Clean artwork, a bit more character
And that’s it. Your lovely clean design now looks like it’s been out enjoying itself for twenty years. You’ve barely had time to finish your coffee.
Try a few textures, see what suits your artwork and stop when you’re happy. You can use the same process on lettering, illustrations, posters and packaging. It doesn’t have to end up on a T-shirt.
If you fancy giving it a go, you’ll find my plastisol texture kit for Illustrator here.
Frequently asked questions
Are these plastisol textures vector files?
Yes. These are vector textures for Adobe Illustrator, so you can resize them without pixelation. The cracks scale with the artwork, so check how they look at your final output size.
Can I use these textures on lettering, illustrations and designs other than T-shirts?
Absolutely. Try them on lettering, illustrations, posters, packaging or logos—anywhere you want that cracked, worn ink appearance. Bold shapes tend to show the effect most clearly. With smaller lettering or delicate details, try a finer texture so your design stays readable.
Do I need Photoshop for this tutorial?
No. This walkthrough uses Adobe Illustrator on desktop and my plastisol texture kit for Illustrator. The Photoshop kit is a separate product.
Which versions of Illustrator does the kit support?
This tutorial uses desktop Illustrator. If you use an older version, contact me before buying and tell me your version number so we can check compatibility. Don’t assume the desktop instructions will work unchanged in the iPad or web versions.
Can I use the textures with live text or PNG and JPEG images?
This walkthrough is written for vector artwork. Live text and placed images may need different preparation, so they shouldn’t be treated as interchangeable with vector shapes.
Placing a PNG or JPEG in Illustrator doesn’t turn it into a vector. If you’re unsure how to prepare your artwork, send me a screenshot before you start.
Can I try a different texture after applying the effect?
Yes. Start with a fresh copy of your original artwork and repeat the steps with another texture. Keep your clean artwork saved separately so you can experiment without rebuilding it.
Why are there coloured lines all over my design?
Illustrator shows coloured outlines when you select vector paths. Click an empty area to deselect everything and see the effect clearly. Those selection outlines aren’t part of your finished artwork.
Why has my artwork disappeared after making the clipping mask?
Check that you’ve selected the intended artwork and texture, that both are visible and unlocked, and that their stacking order matches the tutorial. The clipping path’s position matters.
If you’re still stuck, undo that step and send me a screenshot showing your Layers panel. That’s more useful than repeatedly clicking the same command and hoping Illustrator changes its mind.
Will the cracks show the background underneath?
The intended result is missing areas of ink through which the background shows. To check yours, place a coloured shape behind the finished artwork.
If the cracks stay white, check for a white background or white-filled objects in your design. A white artboard on its own doesn’t prove that those gaps are transparent.
Which plastisol texture should I choose?
Try a few with the same artwork. Compare them at the size you intend to use, and choose the finish that adds character without losing details you want to keep.
Can I send the finished artwork to a T-shirt printer?
Yes. Ask your printer which file format, dimensions and colour setup they need. Order a sample before selling your T-shirts so you can check how the colours and finer cracks reproduce on the garment.
Can I sell T-shirts or client designs made with the kit?
Check the licence supplied with your purchase for the commercial uses it covers. If you’re unsure about merchandise, print-on-demand products or client work, contact me before buying with a brief description of your project.
What if I need help using the kit?
Get in touch with me. Tell me which version of Illustrator you’re using and where you’re getting stuck. A screenshot helps me see what’s happening.
About the author
Written by Simon Stratford, type designer and graphic designer. These are my opinions, reached after too little sleep and too much coffee. You can also follow my antics on @itsmesimonok, or leave a comment below. Despite all the opinions, I’m actually quite nice.