Custom branded t-shirts are a go-to choice for companies building brand awareness, rewarding employees, or creating event merchandise—but the cost varies wildly depending on quantity, quality, and customization complexity. Understanding what drives pricing helps you budget accurately and avoid overpaying for features you don't need. Let's break down the real numbers and what actually affects your final bill.
Price Ranges: What to Expect
Basic custom t-shirt orders typically run $8–$15 per shirt for quantities of 50–100 units with a single-color screen print on standard cotton tees. Bump up to 500+ shirts and you'll drop to $5–$10 per unit. Premium options—thicker fabric, embroidery, multi-color designs, or specialty finishes—push costs to $15–$30+ per shirt even at larger volumes.
Setup fees (also called art or screen charges) usually cost $35–$100 per design, though some suppliers waive them for orders over a certain quantity or offer discounts if you order multiple SKUs at once.
Key Cost Drivers
Quantity The per-unit price drops significantly as volume increases. An order of 25 shirts will cost you roughly double per unit compared to 500 shirts, thanks to fixed production costs being spread across more items.
Blank Shirt Quality Budget tees ($3–$5 per blank) have lighter fabric and basic construction. Mid-range blanks ($5–$8) offer better durability and hand-feel. Premium blanks ($8–$12) use thicker cotton, reinforced seams, or specialty materials like Tri-Blend or organic cotton. Your brand impression depends partly on how the shirt feels.
Printing Method
- Screen Printing: Best for solid colors and 1–4 color designs; costs drop per unit at higher volumes.
- Direct-to-Garment (DTG): Ideal for full-color, detailed artwork; no setup fees, but per-unit cost stays relatively flat regardless of quantity (typically $10–$18 per shirt).
- Embroidery: Premium finish, costs $5–$20+ per shirt depending on design complexity and stitch count.
- Heat Transfer: Budget-friendly for small runs ($6–$12 per shirt), but durability suffers after repeated washing.
Design Complexity Single-color designs cost less than multi-color. Designs with gradients, photographic elements, or intricate details work better (and cheaper) with DTG printing. Simple logos suit screen printing.
Customization Options Adding names, numbers, or variable text increases costs slightly per shirt. Collar tags, side labels, or packaging upgrades (tissue wrap, custom hang tags) add $0.50–$2 per unit.
Timeline and Lead Time Costs
Standard turnaround is typically 7–14 business days after design approval. Rush orders (3–5 days) usually carry a 15–30% premium. Plan ahead and you'll save money—suppliers offer better rates when they're not squeezing production into tight windows.
How to Keep Costs Down
- Order in bulk: Aim for at least 100 units to access better per-unit pricing.
- Simplify designs: Stick to 1–3 colors for screen printing; single-color designs are cheapest.
- Choose versatile blanks: Neutral colors (black, white, navy, gray) have lower minimums and faster turnaround than niche shades.
- Avoid rush fees: Build in 2–3 weeks lead time when possible.
- Compare multiple suppliers: Prices vary; use platforms like Mercoly that help you compare trusted promotional products providers in one place.
- Order matching quantities: If you need 300 shirts and a supplier has a pricing break at 288, you're often better off hitting that tier.
Hidden Costs to Watch
Don't forget shipping (can be $50–$300+ depending on order weight and destination), applicable sales tax, and any fees for custom artwork design if the supplier charges for design work beyond basic logo placement. Some suppliers include shipping in their per-unit quote; others don't—always clarify upfront.
Frequently Asked Questions
Q: What's the minimum order for custom branded t-shirts? Most suppliers accept orders as low as 25–50 units, though per-unit pricing is significantly higher than bulk orders of 100+ shirts.
Q: Can I get a quote without committing to an order? Yes—nearly all promotional products suppliers provide free quotes. Have your logo file ready, specify the quantity, blank style, and printing method, and you'll typically get pricing within 24 hours.
Q: How long do screen-printed designs last after washing? High-quality screen printing holds up for 50+ washes with proper care. DTG prints typically last 20–40 washes before fading, while heat transfers degrade faster (10–20 washes).
Start by defining your quantity needs and design scope, then request quotes from at least three suppliers to compare pricing and quality.