Since nobody else has got back to you..
When the printer is unhappy with the quality, I suspect they actually mean the resolution of the image. They expect 300DPI, so for a ten-inch t-shirt design the width would be 3000 pixels. Check the size of the graphic image that was sent.
The export to AI is probably flattened as a bitmap so it will be uneditable. It's like loading a jpg into a Xara file - it will be a single thing.
Check the export options for ai - particularly the DPI and output document size.
Hope that helps.
Paul
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