Making Custom T-Shirts: What's The Cost?

There are many variables to consider when determining the cost of making your own T-shirt. The price of a blank T-shirt, for instance, can range from $1 to $4, depending on the manufacturer, brand, colour, and cut. Printing methods such as screen printing, heat transfer vinyl, and direct-to-garment printing also vary in price, with the former being more cost-effective for larger orders. Other costs to consider include labour, ink colours, embroidery, shipping, and whether you're printing on one or both sides of the T-shirt. Taking these factors into account, the total cost to produce a basic T-shirt typically falls between $2 and $5.50, with the retail price ranging from $10 to $30 per shirt.

Printing methods: screen printing, direct-to-garment, and sublimation printing

There are several printing methods to choose from when making your own t-shirt, each with its own advantages and disadvantages. Here is an overview of three popular methods: screen printing, direct-to-garment (DTG), and sublimation printing.

Screen Printing

Screen printing is a widely-used and well-known printing method that has been around for a long time. It involves pushing ink through a woven screen or mesh stencil onto the fabric. The ink sits on top of the fabric rather than soaking into it. This method is best suited for solid graphics and simple designs without many small details, as creating stencils for intricate designs can be time-consuming. Screen printing is typically used for bulk orders as it requires a lot of setup time. The cost depends on the number of items ordered and can be expensive for small batches. Screen-printed shirts produce vivid and rich colours and are long-lasting and durable if cared for properly. However, it can be messy and requires a lot of space and a steep learning curve.

Direct-to-Garment (DTG) Printing

DTG printing is a more modern method that uses digital printers to jet water-based ink directly onto the fabric. DTG is ideal for detailed and photorealistic designs with no colour limitations. This method is very sustainable as it allows for printing one-offs, avoiding overproduction and textile waste. DTG is the most cost-effective solution for low-quantity orders and there are usually no order minimums. DTG prints are long-lasting if care instructions are followed, but colours may wash out over time. DTG printers are designed for printing on 100% cotton or cotton blends, and the more cotton in the fabric, the more vivid the print will be.

Sublimation Printing

Sublimation printing is a common method used for printing all-over designs on t-shirts. It involves printing graphics onto special sublimation paper using sublimation inks, which turn into a gas when heat is applied, and then transferring the design onto the t-shirt. This method can result in amazing-looking prints, but it is limited to polyester or polyblend-based t-shirts and there is no white ink available. Sublimation printing is the least expensive to get into at the most basic level, but it can be costly for more complex designs.

Costs: blank t-shirts, printing, cutting, sewing, assembly, packaging, labelling, shipping, and brand

The cost of making a T-shirt varies depending on several factors, including the quantity produced, the materials used, the printing technique, and the scale of production. Here is a breakdown of the costs involved in making a T-shirt, including blank T-shirts, printing, cutting, sewing, assembly, packaging, labelling, shipping, and branding:

Blank T-shirts

The cost of blank T-shirts, also known as "blanks," can range from $1 to $3 per shirt, depending on the quality and type of material used. Cotton is the most common material for T-shirts, but other materials such as polyester or rayon blends may also be used, each with its own associated costs.

Printing

Printing designs or logos on T-shirts can cost between $0.50 and $1.50 per shirt for screen printing and embroidery. Digital printing methods, such as direct-to-garment printing, can be slightly more expensive, ranging from $1 to $3 per shirt. The complexity of the design, the number of colors used, and the printing technique will all impact the cost.

Cutting, Sewing, and Assembly

These processes involve turning the raw materials into T-shirts, including cutting the fabric into the desired shape and sewing the pieces together. The cost for these steps can range from $0.25 to $0.75 per shirt, depending on labor costs and manufacturing expenses.

Packaging, Labelling, and Shipping

Packaging and shipping costs can add approximately $0.25 per shirt for packaging materials and shipping preparation. The actual shipping cost will depend on the distance travelled and the chosen shipping method.

Branding

Branding includes the cost of marketing and promoting the T-shirts to consumers. This can include the cost of creating a brand identity, designing logos, and advertising the product. The cost of branding is often included in the merchant markup, which can range from $7 to $9.50 per shirt.

Overall, the total cost of producing a basic T-shirt typically ranges from $2 to $5.50 per unit. The final retail price of a T-shirt can be significantly higher, ranging from $10 to $30 or more, depending on the brand and the distribution channel.

Design: front, back, multiple colours, custom embroidery, and logos

When designing your own T-shirt, you can choose to have a design on the front, back, or both. The cost of printing on both sides of a T-shirt will be higher than printing on just one side. For example, printing on both sides can increase the cost of a custom T-shirt by $5 per shirt.

You can also choose to have multiple colours in your design. However, this will also increase the cost, as using two or more colours can increase the cost by $2-$3 per shirt. Some companies offer unlimited print colours, but this may be more expensive.

If you want to add a logo to your T-shirt, you can usually upload it to the company's website, and they will print it on the shirt. This is usually included in the price, but some companies may charge extra for this service.

You can also choose to have custom embroidery on your T-shirt. This will usually be an extra fee, and the price will depend on the size and complexity of the embroidery. For example, a small logo on the chest may cost less than a larger design on the back of the shirt.

The cost of designing your own T-shirt will depend on the number of colours, the number of print locations, and any additional features such as embroidery or logo printing. The specific company you choose to print your T-shirts may also affect the price, as different companies may have different base prices and additional fees.

Order quantity: small orders cost more per item, bulk orders are cheaper per item

The cost of making a T-shirt depends on several factors, and the quantity of your order is one of the most significant elements in determining the price per item. When placing an order for custom T-shirts, the larger the order, the lower the cost per shirt.

For instance, if you're purchasing a small number of T-shirts, you can expect to pay retail prices, which are typically around $20-$30 per shirt. This price point may be suitable for personal use, but it is inefficient for distribution or sales. By increasing the order quantity to 50 or more, the cost per shirt decreases to $5-10. If you opt for bulk orders of 100 or more, the price per shirt becomes even more economical, dropping to approximately $5 each.

The relationship between order quantity and cost per item is a crucial consideration when planning a T-shirt business or any endeavour involving custom T-shirts. Maximising your purchase quantity can lead to significant savings. However, it is essential to strike a balance, as buying an excessive number of shirts can result in a loss if they remain unsold or unused.

Additionally, it is worth noting that the base production cost of a T-shirt, which includes the fabric, cutting, sewing, and assembly, typically ranges from $2 to $5.50. The brand then marks up the price to cover marketing and profit, resulting in a retail price of $10 to $30 per shirt. This highlights the substantial difference between manufacturing and retail prices.

Shipping: some companies include shipping costs in the price of the t-shirt

When creating your own t-shirt, it's important to consider the various costs involved, from the price of the blank shirt to any additional features you may want. One factor that can significantly impact the overall cost is shipping. Some companies include shipping costs in the price of the t-shirt, which can affect the final price you pay.

When creating a custom t-shirt, you have the option to choose from various online platforms that offer design and printing services. These companies often provide free shipping, but it's important to note that they typically incorporate the shipping price into the cost of the shirt. This means that even though you may not be paying for shipping separately, it is still included in the total cost of your order. This can impact the overall price you pay for each t-shirt, especially if you order in larger quantities.

While free shipping may seem like a convenient option, it's important to consider the total cost of your order. In some cases, you may find that choosing to pay for shipping separately can result in a lower overall cost per t-shirt. This is because the cost of shipping is not built into the price of the shirt, and you only pay for the actual shipping charges. This can be beneficial if the company offers affordable shipping rates or if you are ordering a large number of t-shirts, as the shipping cost per item may be lower.

When deciding whether to choose free shipping or pay for shipping separately, it's essential to calculate the total cost of your order, including the number of t-shirts, any additional features, and shipping charges. By comparing the total costs, you can make an informed decision that works best for your budget and needs.

Additionally, it's worth noting that the cost of shipping can vary depending on the company and your location. Some companies may have higher shipping charges due to their location or the size of your order. It's always a good idea to research multiple companies and compare their shipping policies and rates to find the most cost-effective option for your custom t-shirt order.

In conclusion, when creating your own t-shirt, be mindful that some companies include shipping costs in the price of the t-shirt. This can impact the overall price you pay, and it's important to consider all factors when calculating the total cost of your order. By comparing prices, shipping rates, and additional features, you can make an informed decision that fits within your budget and ensures you get the best value for your custom t-shirt order.

Frequently asked questions