One Platform. Two Continents.
After four years of growth in the US, Digital On Demand opened a production facility in the Netherlands. Their order management platform was built for one location. Expanding to Europe meant splitting production, inventory, shipping, billing, and accounting across two continents, each with its own rules. PlushWire rearchitected the layers that needed to change, without disrupting the US operation that was already running hundreds of thousands of orders a year.
The Client
Digital On Demand is a US-based print-on-demand company. Their clients are businesses: brands and platforms that sell custom-decorated products to their own customers. Digital On Demand handles production and ships directly to those end customers across more than 110 countries worldwide.
After four years building and scaling operations in Danvers, Massachusetts, having processed hundreds of thousands of orders and integrated with around 70 enterprise clients, the next step was clear: a production facility in Europe, closer to the customers their clients were already serving there.
The Problem
A platform built for one location, and a business that had outgrown it.
- xThe platform managed orders, inventory, production, and billing as a single operation, designed for one facility, with no concept of location separation
- xA second production facility meant splitting everything: each location needed its own production queue, its own inventory, its own pricing in local currency
- xEU shipping required different carriers and integrations: European providers, different label formats, and different regulatory requirements, none of which existed in the platform
- xBilling in euros, European invoicing formats, and VAT-compliant processes required dedicated development across the billing layer
- xThe accounting setup, built around a single QuickBooks account, could not support two separate business entities without significant rework
- xThe US operation could not be disrupted: it was processing tens of thousands of orders per month while the EU build was underway
What We Built
A multi-location platform built to run two continents, and ready for whatever comes next.
The work touched nearly every layer of the platform: production, inventory, shipping, pricing, billing, and accounting. Each area was extended not just for the US and EU, but for any number of future locations, so the next expansion would not mean starting over.
EU and US operations separated cleanly. Each location manages its own.
The production queues, inventory, and order routing were restructured to be location-aware. Each facility sees only what belongs to it. Inventory at one location does not mix with the other. Orders route to the correct facility based on product type and availability.
- Each facility runs its own production queue and workflow
- Inventory separated by location, with real-time visibility per facility and no cross-location mixing
- Orders directed to the correct facility automatically, by product type and availability
- Customer and pricing data extended to handle each location and currency
European shipping, billing, and pricing built for how European operations actually work.
The EU launch required more than adding new carrier accounts. Shipping labels, regulatory requirements, and carrier integrations for Europe differ significantly from the US. Billing in euros, European invoicing formats, and currency-specific pricing all required dedicated development.
- EU carrier integrations with European providers, including European-format shipping labels
- Multi-currency pricing managed per location, in US dollars and euros
- EU billing with euro invoices, European billing address formats, and currency-specific payment workflows
Accounting built for two entities today, and any number later.
The original setup supported a single QuickBooks account. Rather than extending it to handle exactly two, PlushWire reworked that layer to handle any number: each accounting account maps to a location, and adding a new one means connecting another account, with no structural changes required.
- Accounting that runs any number of QuickBooks accounts, each mapped to a production location
- A dedicated EU accounting account integrated and synchronized with EU operations from launch
- Invoicing by period per location: weekly, biweekly, or monthly billing cycles
The Outcome
EU operations live. US operations never stopped. Architecture ready for the next location.
The Netherlands facility went live in a limited rollout and reached full operation as EU demand grew. The US platform kept running through the entire implementation, with no cutover and no disruption to the orders already moving through the queue.
Today Digital On Demand runs a two-continent operation from a single platform. EU orders route to Venlo, US orders route to Danvers, and inventory, shipping, billing, and accounting work independently for each entity from the same system. EU volume has grown past 11,000 orders since launch and keeps climbing.
PlushWire built the platform to expand without replacing it. When the next location is ready, the system already knows how to handle it.
From the people who worked with us
PlushWire was with us through every major chapter of Digital On Demand's growth. For five years, they were there from building our core Order Management System, to a smooth Azure production migration, to going live with our first customer in Europe. Each of those was a major step forward, and none of it would have been possible without their hard work and dedication.
From building out the inventory management system and adapting the Order Management System for new flatbed UV inkjet equipment, to preparing for peak season and launching our new location in Netherlands, they consistently delivered solutions that fit how our production actually works. They took the time to understand complex operational workflows and always proposed the most practical solution, not the most expensive one.
Planning to expand your operations to new locations or markets?
International expansion touches every layer of your operational platform: production, shipping, billing, and accounting. Book a free gap analysis. We will map what your current system can support and what needs to change before the next launch.
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