One of the first questions everyone asks when ordering custom merch: "How much is this going to cost?" The honest answer is: it depends. But "it depends" isn't helpful, so here's a complete breakdown of what actually drives custom merch pricing — and what you can expect to pay for the most common orders.
What Affects Custom Merch Pricing
Four variables drive almost all of the cost variation in custom merch:
- The blank garment — a $4 Gildan tee costs very different from a $18 Bella+Canvas premium tee
- Decoration method — screen printing, embroidery, and DTG have different cost structures
- Quantity — the more you order, the lower the per-unit price
- Design complexity — number of colors, print locations, and artwork detail
Price Ranges by Product Type
| Product | Low End | Mid Range | Premium |
|---|---|---|---|
| Custom T-Shirt | $8–$12 | $14–$20 | $22–$35 |
| Custom Hoodie | $22–$28 | $30–$40 | $42–$60 |
| Custom Polo | $20–$28 | $30–$42 | $45–$65 |
| Custom Hat | $14–$20 | $22–$32 | $35–$55 |
| Custom Tote Bag | $8–$14 | $16–$24 | $26–$40 |
| Custom Jacket | $40–$60 | $65–$90 | $95–$150 |
Prices are per unit at quantities of 24–48 pieces with a standard 1-color, 1-location print. Prices decrease with higher quantities.
How Quantity Affects Price
This is where you can save significant money. Custom merch pricing works on economies of scale — the setup cost is the same whether you print 12 shirts or 500, so the more you order, the less it costs per unit.
| Quantity | Example: Custom T-Shirt (1 color, 1 location) |
|---|---|
| 1–11 pieces | $22–$30 each |
| 12–23 pieces | $16–$22 each |
| 24–47 pieces | $12–$16 each |
| 48–99 pieces | $10–$13 each |
| 100–249 pieces | $8–$11 each |
| 250+ pieces | $6–$9 each |
The sweet spot: Most organizations get the best value ordering 48–72 pieces. You hit the major price break without overcommitting to inventory you might not need.
Screen Printing vs. Embroidery vs. DTG: Cost Comparison
Screen Printing
Most cost-effective for quantities of 12+. Has a per-color setup fee (typically $25–$45 per color, waived at 24+). One color prints cost significantly less than four-color prints. Best for t-shirts, hoodies, and flat garments.
Embroidery
Has a one-time digitization fee ($25–$50) but then is reused for every future order at no charge. Per-unit cost is relatively stable regardless of quantity — typically $4–$8 more per piece than screen printing. Best for polos, hats, and jackets where the premium look is worth it.
Direct-to-Garment (DTG)
No setup fees, unlimited colors at one flat rate. Best for small quantities or complex artwork. Per-unit cost is higher than screen printing at quantity but often lower for 1–11 pieces. Expect $5–$12 more per piece than screen printing at equivalent quantities.
Hidden Costs to Watch For
Some vendors advertise low base prices and make up the difference with add-ons. Here's what to ask about upfront:
- Setup/screen fees — these should be disclosed clearly
- Artwork fees — we don't charge for basic artwork cleanup, but some vendors do
- Shipping — get this included in your quote
- Rush fees — standard turnaround is 7–10 days; rush costs more
- Minimum order fees — some vendors charge a fee for small orders; we don't have minimums
How to Get the Best Price
- Simplify your design — fewer colors = lower cost, especially for screen printing
- Order more — even going from 24 to 48 pieces can drop cost by 20–30%
- Choose the right garment tier — not every order needs a premium blank
- Plan ahead — rush orders cost 15–30% more
- Reuse your logo file — for embroidery, your digitized file is saved for free future use
Get an exact quote for your order
Tell us what you need and we'll respond within 24 hours with exact pricing — no guesswork, no hidden fees.
Get a Free Quote →