The Cost Of T-Shirts: How Much Does It Really Cost?

The cost of a t-shirt can vary depending on several factors, including the type of shirt, the printing method, additional features, and brand name. Custom t-shirts typically range from $7 to $50, with an average price of around $20. The price of a t-shirt also depends on the number of shirts ordered, with bulk orders often resulting in a lower cost per shirt. The quality of the shirt, such as the fabric type and size, also impacts the price. For example, a standard cotton t-shirt may cost $1 to $3, while premium shirts made with Pima or Egyptian cotton can be more expensive. Other costs to consider include customization methods like digital printing or screen printing, which can add $25 to $50 or more to the price of a shirt. Ultimately, the final retail price of a t-shirt includes markups for merchant profits, marketing, shipping, and brand value, which can result in a significant difference between the manufacturing and retail costs.

Cost of customisation

The cost of customising a T-shirt varies depending on the number of shirts ordered, the type of shirt, the printing method, additional features, and how soon you need it. Generally, you can expect to pay anywhere from $10 to $50 for a custom T-shirt, with an average price of around $20 per shirt.

Quantity of Order

The size of your order is one of the most significant factors in determining the cost per item. All print companies have volume discounts built into their pricing, but how much of a discount and how that discount is applied varies. For example, some companies have volume price breaks set at certain tiers, such as quantities of 12, 36, 72, 144, and so on. This can push customers to order more than they need to get a better price per piece. However, some companies, like RushOrderTees, offer rolling volume pricing, with incremental discounts for each additional item ordered.

Quality of Shirts

The quality of the shirts also affects the price. While all T-shirts have sufficient construction quality, with well-stitched seams that will hold up for years, premium tees have additional reinforcements and details, providing superior durability and fit. Premium cotton shirts tend to be 'ring-spun', which is softer and smoother for printing, while budget tees are typically 'carded-open-ended' with a rougher print surface. Higher-end premium shirts are made with Pima or Egyptian cotton. Tri-blend tees, which combine cotton, polyester, and rayon, are in high demand and have the highest price point.

Number of Print Locations

Multiple print locations increase the cost of each shirt significantly. For example, a T-shirt with prints on the front, back, and both sleeves can be as much as twice the price of a shirt with a single print location, depending on the number of colours used.

Customisation Method

The customisation method can also impact the price. Digital printing is more cost-effective for lower-quantity orders and designs with many colours, while screen printing is ideal for larger quantities as the cost per shirt drops significantly with volume orders. Embroidery is typically used for smaller customisations, such as a logo, and is priced based on the thread count or stitch count.

Number of Ink Colours

For screen-printed T-shirts, the higher the number of colours in the design, the higher the cost per piece. This is because a different screen needs to be set up for each colour, increasing production time and costs.

Additional Personalisation

Adding custom personalisations, such as names and numbers on a sports team shirt, will also increase the cost of the T-shirts.

Turnaround Time

Most printing companies charge extra for rush orders, with tiered pricing for different turnaround times.

Fees and Set-up Charges

Some smaller print shops will include various fees as line items in their invoices, such as screen setups, inks, special handling, delivery, and packaging, which can increase the final cost of the order.

Fabric type

The fabric type is a crucial factor in determining the cost of a T-shirt. The most common fabric options are cotton, polyester, or a blend of the two.

Cotton

Cotton is a natural, comfortable, and soft fabric that is widely considered the best fabric for everyday T-shirts. It is praised for its breathability, moisture absorption, and biodegradability. However, cotton tends to hold moisture, resulting in longer drying times, and is prone to wrinkling and shrinking. Cotton is also susceptible to colour fading over time.

Cotton T-shirts can be made from various types of cotton, including:

• Ringspun cotton: More durable, softer, and more expensive than regular cotton due to its spinning process.
• Combed and ringspun cotton: Even softer than ringspun cotton as it undergoes an additional combing process to remove impurities, creating a smoother surface for printing.
• Organic cotton: Grown without synthetic fertilizers, making it a costlier and more ecological option.
• Slub cotton: Produced with knots and twists, giving the fabric an uneven look and feel, making T-shirts more breathable and less clingy.
• Pima cotton: Has a longer fibre than other types of cotton, resulting in an ultra-smooth and soft feel, along with resistance to wrinkling and fading.

Polyester

Polyester is a synthetic fabric, usually made from plastic, that is moisture-wicking and quick-drying. It is resistant to stains, odours, wrinkles, and shrinking. However, polyester is not as breathable as cotton, tends to pick up static, and may irritate the skin of some wearers. Additionally, it is not biodegradable.

Cotton/Polyester Blends

Cotton/polyester blends combine the benefits of both fabrics, offering softness, comfort, quick-drying properties, wrinkle and shrink resistance, and durability. These blends are generally more affordable than pure polyester. However, they can still cling to the body, irritate the skin, and have limited printing options like pure polyester.

Common cotton/polyester blends include:

• 90% cotton/10% polyester: Soft, breathable, and less prone to shrinking than pure cotton.
• 65% polyester/35% cotton: The most popular blend, balancing shrink resistance and cost.
• 50% polyester/50% cotton: More breathable and popular for sports and exercise.

Linen

Linen is a natural fabric made from flax plant fibres, known for its lightweight and breathable qualities. It is an excellent choice for warm weather, providing a blend of comfort, style, and sustainability. Linen is strong, durable, and absorbs moisture without feeling damp. However, it requires regular ironing and is generally more expensive than other fabrics.

Rayon

Rayon is a manufactured fibre made from regenerated cellulose fibres, typically wood pulp. It is soft, silky, lightweight, and absorbent, with an elegant look. Rayon can be more expensive than cotton or polyester, but it shares characteristics with both. It can also be blended with synthetic fabrics like modal for added stretch and elasticity.

Other Fabrics

Other fabrics used for T-shirts include lycra, viscose, bamboo, hemp, modal, jersey, and more. Each fabric has unique properties and offers varying levels of comfort, durability, and suitability for different climates and activities.

Size

The size of a T-shirt is a significant factor in determining its cost. While standard sizes (XS-XL) typically fall within the same price range, larger sizes such as 2XL and above can be significantly more expensive. This is due to the increased material and production costs associated with larger sizes. For example, a 2XL shirt can cost upwards of 25% more than a standard size, with the price increasing to 35% and 50% for 3XL and 4XL respectively. This pricing discrepancy is often not reflected in retail pricing, but it is an important consideration when purchasing custom T-shirts or ordering in bulk.

When it comes to custom T-shirts, the size of the order also plays a crucial role in determining the cost per item. Most print companies offer volume discounts, with prices decreasing as the quantity of the order increases. This means that buying in bulk can result in significant cost savings. However, it is important to strike a balance, as ordering too many shirts can result in unnecessary expenses if they are not all utilised.

The type of shirt also influences the price, with premium tees offering superior durability and fit at a higher cost. These premium options often feature additional reinforcements and details, such as side seams, shoulder-to-shoulder taping, and double-needle stitching. Well-known brands, such as Nike or Adidas, also tend to have a higher price point due to their established reputation and brand value.

In addition to the size of the shirt and the quantity ordered, other factors that can impact the cost of a T-shirt include the printing method, number of print locations, customisation options, and turnaround time. Digital printing, for instance, is typically more cost-effective for lower-quantity orders and designs with multiple colours, while screen printing is more economical for larger quantities with simpler designs.

Overall, the size of a T-shirt can have a notable impact on its cost, especially when coupled with other factors such as order quantity and customisation options. Understanding these variables can help individuals and businesses make informed decisions when purchasing T-shirts, ensuring they get the best value for their money.

Brand

A successful brand can be built by investing $1 or $2 more in the production of a T-shirt to enable charging $5-10 more at retail. This can create customers who love the product, spread the word, and come back for more. It is important to price T-shirts for what they are worth, as pricing them for less than they are worth will lead to customers perceiving them as less valuable.

Additionally, retail add-ons such as custom garment tags, branded hang tags, and bagging can help build legitimacy around a brand, although they increase the total cost of the project. Brand names can also influence the price of a T-shirt, as some brands are known for their high quality. For example, household names such as Hanes offer tagless T-shirts in lots of colors and sizes, with prices ranging from $10 to $25.

The number of ink colors used in a design can also impact the cost of a T-shirt, with companies typically charging more to print with several colors. For instance, using two or more colors can increase the cost by $2-3 per T-shirt.

Additional features

The cost of a custom t-shirt can vary depending on the additional features you choose. For example, printing on a coloured shirt instead of a plain white shirt will increase the price by $1 to $5 per shirt, depending on the quantity ordered. Using multiple colours of ink can also increase the cost by $2 to $3 per shirt. If you want to print on both the front and back of the shirt, this will add around $5 to the cost per shirt.

Some companies offer custom embroidery for an additional fee. Other add-on services include tag printing, hem tags, foil printing, folding, and polybagging. These services typically cost between $0.30 and $2 per shirt for tag printing, $0.50 to $2 per shirt for hem tags, $1.50 to $4 per shirt for foil printing, and $0.45 to $1.90 per shirt for folding and polybagging.

The brand of t-shirt you choose will also affect the cost. Well-known brands such as Nike or American Apparel typically have a higher price point than lesser-known brands like Gildan or Tultex. For example, a Gildan tee usually costs under $10, while a Nike tee is unlikely to be found for less than $20.

The quality of the t-shirt is another factor that influences the price. Budget tees are typically made with lower-quality materials and construction, while premium tees offer superior durability and fit, featuring details like side seams, shoulder-to-shoulder taping, and double-needle stitching. Premium tees are usually priced higher than budget or standard options.

Finally, the customization method can impact the cost. Digital printing is generally more cost-effective for small orders or designs with many colours, while screen printing is more economical for larger quantities or simpler designs. Embroidery is another option, typically used for smaller customizations, and is priced based on the thread count or the number of stitches required.

Frequently asked questions