T-Shirt Printing Cost Calculator
Calculate the cost per printed t-shirt including blank garment cost, per-shirt print cost, and setup fees amortized over the run quantity. Enter your print run size, blank shirt cost, printing rate per shirt, and total setup fees. The calculator shows cost per shirt and a suggested retail price at your chosen markup.
T-shirt printing cost formula
Setup cost per shirt = total setup fees / quantity
Total cost per shirt = blank cost + print cost + setup cost per shirt
Suggested retail = total cost per shirt * markup multiplier
Total run cost = total cost per shirt * quantity
This model applies to screen printing, DTG, embroidery, and heat transfer print methods. For screen printing, setup fee covers screen making per color. For DTG, setup fee is typically zero or minimal. Always confirm current rates with your printer.
Reducing per-shirt printing costs
- Increasing run quantity is the most effective way to reduce per-shirt cost because setup fees are spread over more units.
- Reducing the number of colors lowers screen printing setup costs by $20 to $50 per color eliminated.
- Choosing a standard blank shirt (e.g., Gildan 5000) instead of premium blanks reduces per-shirt cost by $3 to $10.
- Printing on one side only (front or back) instead of both reduces print cost per shirt.
- Consolidate multiple designs into one print run where possible to share setup costs.
T-shirt printing costs: frequently asked questions
How is the cost per printed t-shirt calculated?
Cost per shirt = (blank shirt cost + printing cost per shirt) + (setup fee / quantity). Setup fees are one-time costs (screen setup, art separation) amortized over the print run. The more shirts in a run, the lower the per-shirt cost because setup fees are spread over more units.
What is the difference between screen printing and DTG printing costs?
Screen printing has a high setup fee (per screen/color) but a lower per-shirt cost at volume, making it economical for runs of 24 or more. DTG (Direct-to-Garment) digital printing has no setup fee but a higher per-shirt cost, making it better for small runs of 1 to 12 shirts. Setup fees for screen printing typically run $20 to $50 per color.
How many colors affect screen printing cost?
Each color in a screen print design requires a separate screen and ink pass, adding setup cost (typically $20 to $50 per screen) and print time. A 1-color print is cheapest; each additional color adds cost. Full-color photo-realistic designs are usually cheaper with DTG, which prints all colors in one pass.
What is a typical retail markup for custom printed t-shirts?
Custom apparel sellers typically use a markup of 2x to 3x the total cost (blank + printing) for retail. For branded merchandise or event shirts, markup is often 3x to 4x. Always include setup fee amortization in your base cost before applying markup.
What is the minimum order quantity for screen printing?
Most screen printing shops have a minimum order of 12 to 24 shirts per design, because setup costs are not economical for smaller runs. For single-shirt or very small runs, DTG or heat transfer printing is more cost-effective despite the higher per-shirt rate.
Official sources
- U.S. Small Business Administration, Pricing Strategy: SBA Manage Your Finances.
- U.S. Bureau of Labor Statistics, Apparel Manufacturing: Apparel Manufacturing Industry.
Reviewed by the CalculatorHub team, edited by James Graham, 14 June 2026. See our methodology.