The full cost table
| Quantity | Cheapest method | Per-shirt (DTG) | Per-shirt (screen) | Per-shirt (premium B+C DTG) |
|---|---|---|---|---|
| 1 | DTG (no setup) | $15.99–$18.99 | Not viable | $19–$24 |
| 6 | DTG | $13–$17 | $14–$18 (setup heavy) | $17–$22 |
| 25 | Screen edges ahead | $10–$14 | $9–$12 | $14–$18 |
| 50 | Screen | $9–$12 | $7–$10 | $12–$15 |
| 100 | Screen | $8.99–$12.99 | $5.50–$8 | $11–$14 |
| 200+ | Screen | $8.50–$11 | $4–$5.50 | $9–$12 |
The crossover point: ~25 units
DTG and screen printing reach cost parity at approximately 25 units. Below 25: DTG wins (no setup cost). Above 25: screen printing wins (setup cost amortised across enough shirts).
The Underground Shirts analysis of 200 shirts: screen printing lands at $4–$5.50/unit vs $9–$11/unit for DTG — a 2x difference. At 200 shirts, the method you choose is worth $900–$1,300.
Hidden fees that blow the headline number
Every printer has a headline per-unit number. Every printer also has fees that don’t show up until checkout:
- Art prep / vectorisation: $20–$60 one-off for screen orders. CustomInk includes it; many local shops don’t.
- Multi-colour upcharges (screen): $0.25–$0.75 per additional colour per side. A 4-colour front + 2-colour back can double the effective print cost.
- Premium blank upcharge: Bella+Canvas 3001 adds $1.50–$3.50/tee vs Gildan 64000.
- Rush fees: 25–60% surcharge for sub-7-day turnaround. Often masked as “expedited shipping.”
- Sleeve/neckline/inside-tag prints: $1–$3 each additional location.
See the full list at hidden fees in t-shirt printing.
The wrong-choice pattern
The buyers who need 10 shirts for an event choose Custom Ink (24-unit minimum — they end up paying for 14 shirts they don’t need). The buyers who need 200 shirts for a business choose Printful (which charges 3x the per-unit cost of screen printing at that quantity). Neither error is obvious on the homepage — both sites emphasise the other buyer type’s ideal scenario.
The right question before you contact any printer: how many shirts do you actually need? The answer determines the method. The method determines the provider.
Scenario guide
| Scenario | Quantity | Recommended method | Recommended provider |
|---|---|---|---|
| Single gift tee | 1 | DTG | Printful or Zazzle |
| Small group (staff, team) | 6–24 | DTG | Printful (consistent quality) |
| Event (charity run, wedding, etc.) | 25–100 | Screen printing | RushOrderTees |
| Event (corporate, large budget) | 100–500 | Screen printing | Custom Ink (phone support worth premium) |
| Band merch tour | 100–200 | Screen printing | RushOrderTees or local printer |
| POD store (variable demand) | 1 per order | DTG POD | Printful or Printify |
| Large brand order | 500+ | Screen printing | Local screen printer or RushOrderTees |
Related pages
- Decision wizard — answer 5 questions, get a personalised recommendation
- DTG vs screen printing — the method crossover analysis
- Hidden fees in t-shirt printing — the full fee checklist
- Event tees under 100 units — use-case guide for event organisers