
The good people at Camp Tannadoonah who always accept everything I say from a design consulting perspective with absolutely no hair pulling, wailing or gnashing of teeth recently directed me to “draw a Polar Bear for a T-shirt design.” Projects like this remind me of why I enjoy being a designer. Whether or not it’s the best single-color vector Polar Bear you’ve ever seen is, in this case, subordinate to the fact that it was really really fun. I can’t wait for these shirts to come out so I can proudly wear one around until I wear holes in it.
The design was done in Illustrator. I built from this pencil sketch:

I generally sketch on a section of a long roll of cheap tracing paper. It takes the pressure off to come up with a perfect sketch because you can always rip of another sheet and trace over it if you mess up. Also the paper kind of carries with it the idea that, under no circumstances are we producing a show piece here. It’s crappy paper, it’s not going to last. That reduces some of the pressure to be an anal perfectionist as well.
I don’t have a scanner so I literally took a snap with my Nikon D40, used Photoshop to convert to grayscale and then used adjustment layers to lighten the image up and bump the contrast a bit. I save files like this out as .tiff when I’m going to be using them in Illustrator. I’m pretty sure I do this because .tiffs end up full resolution when placed in Illustrator. (The truth I do it because that’s how I’ve always done it, but I think that resolution is why i started doing it).
Clearly, the sketch is too detailed (even as loose as it is) to make a good t-shirt. I’m going to be relying on a screen printer to reproduce this, and I’d prefer not to give the poor guy a migraine, so my illustration has to be designed with screen printing in mind. That means no little tiny hair lines, no gradients, etcetera. One ink, big thick lines.
I drew the basic outline shapes with the pen tool and bumped the stroke weight up to thicken them, then drew in the white area of the bear behind the stroke outlines. I expanded the strokes. This is the result in outline preview:
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The thick, double outline is the expanded stroke. The rough, jagged line that runs all the way around the bear shape is the white fill area in the background. I can further refine this shape, so that I’m providing one, easy to print vector to my printer though. Ideally, I want to send him one solid white shape with no extra vectors to add complexity. The first step is to use the Pathfinder to merge the ice cube shape and the white background of the bear into one shape. Then I select this newly created white shape and the blue expanded outlines (making sure that the outlines are on top). Use pathfinder one more time to take the expanded outlines and use them to clip the white shape underneath. Below is the result:

Much simpler. Much easier for anyone with a basic knowledge of Illustrator to open and immediately understand. A designer’s life is made so much easier when he isn’t putting unnecessary hurdles in the path of his production vendors. At this point, if you’re really anal (as I am) the one thing that’s left is to use pathfinder to take the eyes and nose and clip them out of our white shape.