The Cost Of T-Shirt Printing: A Comprehensive Guide

The weight of a t-shirt is an important consideration, especially when it comes to shipping costs. The weight of a t-shirt varies depending on the material, size, and thickness of the fabric. On average, a t-shirt weighs between 4 and 7 ounces or about 120 to 155 grams. Fabric weight is typically measured in ounces per square yard or grams per square meter (GSM). A higher GSM indicates a denser and heavier fabric, while a lower GSM indicates a lighter and less dense fabric. When it comes to shipping, it's important to consider the weight of the packaging and any additional items included, as these can add to the overall weight.

T-shirt weight for postage

The weight of a T-shirt varies depending on the size, fabric, and brand. For example, a small Fruit of the Loom Budget T-shirt weighs 128 grams / 4.5 oz, while a medium Gildan Softstyle T-shirt weighs 138 grams / 4.86 oz, and an XL American Apparel 50/50 T-shirt weighs 156 grams / 5.5 oz. On average, a T-shirt will probably weigh between 130 and 150 grams.

When it comes to postage, the weight of the packaging also needs to be considered. For example, a plastic mailbag that can hold one folded T-shirt typically weighs around 15 grams, and including a packing note or postcard can add another 6 grams.

In terms of postage options, T-shirts can often be sent as large letters if they are folded up properly with a piece of cardboard to stiffen the packet. For example, in the UK, a large letter must be no thicker than 25mm and no larger than 353mm x 250mm to qualify for the cheapest type of parcel post.

If you are sending multiple T-shirts or bulkier clothing items, you may need to use a small parcel service. Some couriers, such as UPS, Evri, and ParcelForce, offer large parcel services for heavier or bulkier items.

It is always a good idea to round up when calculating postage weights and remember that shipping costs can increase significantly when sending items to another country.

T-shirt printing costs

The cost of T-shirt printing varies depending on several factors, including the number of T-shirts being printed, the printing deadline, the number of colours used, the T-shirt brand and size, and any additional services required.

Number of T-shirts

One Hour Tees offers custom T-shirt printing services with prices that decrease for larger orders. For instance, an order of twenty Gildan 2000 T-shirts averages $18 per shirt, while an order of 100 shirts averages $9 per shirt.

Printing deadline

The printing deadline also affects the cost of T-shirt printing. For example, One Hour Tees offers printing services with the following price ranges:

• 7+ business days: $7.99+
• 6 business days: $9.99+
• 4-5 business days: $11.99+
• 3 business days: $14.99+
• 2 business days: $16.99+
• Next business day: $18.99+
• Same day: $21.99+

Number of colours

The number of ink colours used in the design also influences the printing cost. CustomInk's sample pricing for the Hanes Tagless T-shirt with one ink colour on one side ranges from $10 to $24 per shirt.

T-shirt brand and size

The brand and size of the T-shirts can also impact the printing cost. Well-known brands like Nike or American Apparel typically have higher price points compared to lesser-known brands like Gildan or Tultex. Additionally, extended sizes (2XL-3XL) may increase the cost per shirt.

Additional services

Add-on services, such as custom tag printing, hem tags, foil printing, folding, and polybagging, can further increase the overall cost of T-shirt printing. These services typically range in price from $0.30 to $4 per shirt, depending on the specific service.

T-shirt weight variations

T-shirts come in a variety of weights, depending on factors such as material, size, and thickness. A standard medium-sized t-shirt made from cotton fabric typically weighs between 4.5 to 5.5 ounces or 130 to 155 grams. However, t-shirt weights can vary significantly, ranging from lightweight options at 3.5–4.5 oz/yd² to heavyweight varieties at 5.3–6+ oz/yd².

Fabric weight is commonly measured in grams per square meter (GSM) or ounces per square yard (oz/yd²). A higher GSM or oz/yd² value indicates a denser and heavier fabric. For instance, a typical t-shirt falls within the range of 4–7 oz/yd².

The weight of a t-shirt also depends on the yarn count, measured in "singles." A higher singles count indicates a finer, softer, and lighter fabric, while a lower singles count results in a coarser and heavier t-shirt. Premium t-shirts often use 30 singles yarn, while basic, heavier t-shirts may use 18 singles yarn.

Lightweight t-shirts, weighing 120–150 GSM or 3.5–4.5 oz/yd², are highly regarded in the clothing industry for their comfort and versatility. They are ideal for warm weather and physical activities due to their breathability and lightweight nature. However, they may not be as durable as heavier t-shirts.

Mediumweight t-shirts, on the other hand, strike a balance between comfort, durability, and versatility. Falling within the 150–180 GSM or 4.5–5.3 oz/yd² range, they are suitable for various climates and offer a polished look with a touch of added resilience.

Heavyweight t-shirts, weighing 180–200+ GSM or 5.3–6+ oz/yd², offer a noticeable difference in feel and comfort. They are known for their super soft touch, smooth and sturdy feel, and stylish silhouette. While they may not be the first choice for breathability in hot summers, they are perfect for cooler weather. Heavyweight t-shirts are also excellent for printing, as they produce crisp and long-lasting designs.

The weight of a t-shirt is an essential consideration, especially when it comes to shipping costs, comfort, durability, and printing quality.

T-shirt packaging

• Make your branding part of your packaging: Incorporate your brand's visual elements, such as colours, shapes, or logos, into the packaging design. For example, Amon Clothing includes triangles in their packaging design, reflecting their brand identity.
• Think outside the box: Literally! Instead of a traditional box, consider using a cool crate or a unique container, such as a polyfoam cup, an ice cream bucket, or a roll. Baffs, for instance, chose rolling as an unconventional option, ensuring their tees arrive wrinkle-free.
• Go for eco-friendly materials: Choose packaging that is environmentally friendly, such as blank cardboard, earthy colours, or recycled paper. This can help create a positive brand image, as many consumers appreciate sustainable practices.
• Mix up your materials: Experiment with different materials such as PVC or brown paper bags. These materials can add a unique touch to your packaging and make it stand out.
• Display appeal: Create packaging that looks great on its own but also complements your product when stacked or displayed together. For instance, the T-shirt boxes for the Swedish clothing brand Cicatriz look appealing when stacked together.
• Embrace your uniqueness: Choose a logo or symbol that conveys your brand's personality. For example, Forever Gold Clothing selected a pineapple logo to convey a positive, appealing, and unusual brand image.
• Teamwork: Collaborate with artists or designers to create contemporary designs for your packaging. Fossil, for instance, worked with artist Dolan Geiman on contemporary folk tees, which were sent in boxes inspired by Fossil's well-known watch tins.
• Make a statement: Design your packaging to intrigue and excite your customers. For instance, the box from INDISODER hints at something cool awaiting the customer inside.
• Make a funny face: Add a touch of humour to your packaging design, such as a smiley face or a playful illustration. This can bring a smile to your customer's face and create a positive association with your brand.
• Display your unique selling points: If your T-shirts have special features, such as being high-tech or environmentally friendly, let your customers know right away through your packaging. For example, Tom Dixon's polo shirts for Lacoste come in boxes that highlight these unique qualities.
• Neat and tidy: Keep your packaging simple and organised. Publish's Second Chance line of T-shirts uses tidy rolls of fabric made from recycled paper, creating a neat and eco-friendly presentation.
• Make it practical: Design your packaging to be useful even after the product is used. For instance, HangerPak's boxes transform into actual clothing hangers, and Hobo and Sailor's soft cloth bags are cute and practical for reuse.

These tips and examples can inspire you to create memorable and engaging T-shirt packaging that enhances your brand's image and resonates with your customers.

T-shirt printing services

Types of Printing Techniques:

• Direct-to-Garment (DTG): This method involves applying ink directly to the T-shirt using eco-friendly, water-based inks, resulting in a soft feel print.
• Direct to Film (DTF) or Transfer: This technique is ideal for single-colour text or simple designs and includes vinyl or flock applications.
• Screen Printing: This traditional method uses a mesh screen and ink-blocking stencil to apply each colour separately, ideal for bulk orders.
• Embroidery: For a durable and professional look, embroidery is a popular choice, especially for business uniforms.

Choosing the Right T-Shirt:

• Material: Consider the fabric, such as 100% cotton for breathability or performance fabric for moisture-wicking properties.
• Style: Choose from short-sleeve, long-sleeve, crewneck, V-neck, or tank tops to suit your preferences and the intended use.
• Size: Ensure you select a provider that offers a range of sizes for adults and children to fit everyone in your group.

Customisation Options:

• Design: You can usually upload your own artwork, logo, or design to be printed on the T-shirts.
• Text: Add custom text with a choice of over 500 fonts to include names, slogans, or other personalised messages.
• Colours: Some providers offer unlimited print colours, allowing you to create vibrant and eye-catching designs.

Ordering Process:

• Select your T-shirt style and sleeve length.
• Upload or create your design, adding any custom text or artwork.
• Preview and share your design with others before finalising your order.
• Check for minimum order quantities, as some printing techniques may require a minimum number of items.

Cost and Delivery:

• Costs can vary depending on the quantity, type of T-shirt, and printing technique chosen. Some providers offer discounts for bulk orders or charities.
• Delivery times and charges will differ, so check these details before placing your order to ensure they meet your requirements.

Frequently asked questions