When you're ordering custom apparel for your team, business, or event, the base garment you choose makes a massive difference in both price and final quality. T-shirts, hoodies, and jackets each have distinct cost structures, production timelines, and design limitations that directly affect your bottom line.
Understanding Base Garment Costs
T-shirts are the entry point for custom apparel. A standard blank t-shirt from a supplier like Gildan or Hanes typically runs $2.50–$4.50 per unit depending on weight and quality, with heavier 6.1 oz cotton commanding higher prices than lighter 4.5 oz blanks. Hoodies sit in the mid-range: expect to pay $8–$15 per blank garment, with premium options (fleece-lined, heavyweight) approaching $18. Jackets are the premium option, with blank prices ranging from $15–$35+ depending on material (windbreaker, nylon, canvas) and construction quality.
These base costs matter because they're the foundation before screen printing, embroidery, or other customization is added.
Screen Printing Costs by Garment Type
Screen printing setup and production vary significantly across garment types. T-shirts typically incur a one-time setup fee of $50–$100 per color (covering screen creation and exposure), then $1.50–$3 per print per color, depending on order volume and design complexity.
Hoodies follow a similar setup structure but run slightly higher per unit—usually $2–$4 per print—because the thicker fabric requires more ink and longer curing times. The hood itself adds complexity if you're printing there.
Jackets present the biggest printing challenge. Setup fees remain comparable ($50–$100 per color), but per-unit printing costs jump to $3–$6 because of:
- Increased fabric thickness and surface area
- Need for specialized presses or manual curing
- Higher ink volume required
- Potential for printing on multiple panels
Hidden Costs and Considerations
Beyond garment price and printing, several factors inflate your total spend:
- Setup fees reset per order unless you're ordering the same design repeatedly from the same printer
- Color count matters: Each additional color adds setup costs and increases per-unit printing costs
- Location on garment: Back prints, front pockets, and sleeves all cost differently
- Minimum order quantities: Most printers enforce minimums of 12–24 units for custom orders to justify setup
- Rush orders: Expedited turnaround (48–72 hours instead of 7–10 days) typically adds 20–40% to your total cost
- Finish options: Curing methods, water-based inks, or eco-friendly finishes affect pricing
Price Comparison at Scale
For a 50-unit order with a simple two-color front logo:
| Garment | Blank Cost | Setup | Print Cost/Unit | Total Print Cost | Approximate Total | |---------|-----------|-------|-----------------|------------------|-------------------| | T-Shirt (5.3 oz) | $3 | $100 | $2.50 | $125 | $275–$300 | | Hoodie (7.8 oz) | $10 | $100 | $3 | $150 | $650–$700 | | Jacket (Nylon) | $18 | $120 | $4 | $200 | $1,100–$1,200 |
These are ballpark figures; actual pricing varies by vendor, location, and ink type.
When to Choose Each Garment
Go with t-shirts if you're on a tight budget, need quick turnaround, or prefer simplicity. They're ideal for promotional items, casual team events, or testing a design before scaling up.
Choose hoodies for higher-perceived value and comfort, especially for seasonal promotions or employee gifts. They're durable enough for regular wear and justify slightly higher pricing without looking extravagant.
Order jackets only when durability, branded visibility, and premium perception matter. They're perfect for executive teams, outdoor events, or merchandise that customers will wear repeatedly in public.
Finding the Right Printer
Pricing alone doesn't tell the whole story. Look for printers who can:
- Show samples of previous work on similar garments
- Explain their setup and per-unit costs transparently
- Offer competitive minimum orders (some allow 6–12 units instead of 24+)
- Provide fast turnaround without exponential rush fees
- Handle color matching and have Pantone or CMYK standards
Platforms like Mercoly let you compare quotes from multiple custom apparel providers in your area, making it easier to spot fair pricing and quality consistency.
Frequently Asked Questions
Q: What's the cheapest way to order custom apparel? Order t-shirts with a single-color front print in the largest minimum quantity (usually 50+) your printer accepts, since per-unit costs drop significantly at higher volumes.
Q: Can I print on both sides of a jacket without doubling the cost? Not quite—most printers charge 60–80% of the second print's cost if it's the same design, but setup fees still apply separately for each location.
Q: How long does custom apparel take from order to hand-off? Standard production is 7–10 business days for most garments; t-shirts can sometimes ship in 5–7 days if you skip customization or use stock designs.
Start comparing quotes from local screen printers today to lock in the best price for your custom apparel project.