How Much Does Bulk T-Shirt Printing Really Cost?

How Much Does Bulk T-Shirt Printing Really Cost?
Nov 22, 2024

How Much Does Bulk T-Shirt Printing Really Cost?

Cost considerations for Screen Printing bulk orders in the UK

When printing t-shirts in bulk for your UK business, understanding the true cost is essential. Asking “How much does bulk t-shirt printing cost?” isn’t just about the final price. It’s about knowing what drives it. The cost per unit can vary depending on factors like order quantity, fabric type, printing technique and more.

These cost elements play a big role in your budgeting, product pricing, and overall profitability.

How Much Does Bulk T-Shirt Printing Cost?

Balancing Quality and Budget.

Accurately calculating bulk printing costs helps UK businesses make smarter decisions. Your per-shirt price can shift significantly based on variables such as quantity, fabric choice, and print method.

This guide outlines the main factors influencing bulk t-shirt printing costs in the UK. We’ve included examples, industry insights, and expert advice so you can approach your next order with confidence. Whether you’re a startup or a growing brand, this knowledge will help you budget smarter and protect your margins.

Quantity-Based Discounts for Bulk T-Shirt Orders

The number of shirts you order is one of the biggest cost factors. Orders over 500 units sometimes qualify for discounts between 10% and 50%.

For example, a small batch might cost £5 per shirt. But a larger run — 1,000 units or more — could lower that cost to £3.50 or even £2.50 each. These savings can have a major impact on your bottom line, so always consider quantity-based pricing when planning your order.

Comparing Fabric Costs for Bulk T-Shirt Printing

Fabric choice plays a big role in your per-shirt cost. Polyester t-shirts typically cost between £2 and £4 each.

100% cotton shirts tend to be slightly more expensive, averaging £3 to £5 per unit. Blended materials usually fall somewhere in between.

Choosing the right fabric means balancing quality, customer preference, and budget. Premium matters, and finding the right balance is most important.

Evaluating Printing Technique Costs

Your chosen printing method also affects the total cost. Screen printing is often the most affordable option for larger runs.

It works best for designs with fewer colours — 1 to 2 colours offer the best value. However, as the number of colours increases, so do the setup costs, since each colour requires its own screen.

Direct-to-Garment (DTG) printing, on the other hand, has no screen setup fees. But it’s usually more expensive, costing between £8 and £15 per shirt. You may find, though, that it becomes the affordable option for your needs if you are printing smaller runs with quality garments.

Accounting for Additional Colour Costs

Each additional colour in a screen print increases the setup and printing time. As a result, the cost rises.

For example, a one-colour design might cost £3 per shirt. A four-colour design could push the price up to £8 or more.

If you’re on a budget, simplify your colour palette to control costs.

Factoring in Rush Fees for Expedited Turnaround

Need your shirts in a hurry? Expect a premium. Fast-track production often adds 10% to 20% to your total cost.
Avoid rush fees by planning ahead and giving your supplier enough lead time. Standard production timelines can save you significantly.

Bulk T-Shirt Printing Cost Case Studies

To help visualise costs, here are three real-world examples:

  • Case Study 1: 1,000 Cotton Shirts with 2-Colour Screen Print
    Company A paid £4,500 for 1,000 cotton t-shirts with a 2-colour screen print. That’s £4.50 per shirt, including a 25% discount.
  • Case Study 2: 250 Poly-Blend Shirts with 4-Colour DTG Print
    Company B spent £3,750 for 250 poly-blend t-shirts printed via DTG. The cost was £15 per shirt. No bulk discount applied, but DTG allowed unlimited colours without extra charges.
  • Case Study 3: 2,500 Gildan Shirts with 1-Colour Screen Print
    Company C ordered 2,500 Gildan t-shirts with a simple 1-colour screen print. Their total cost was £11,250 — just £4.50 per shirt — after securing a 40% discount.

Expert Advice on Calculating Bulk T-Shirt Printing Costs

“The key is to understand your cost drivers and negotiate the best rates with UK suppliers. Don’t just go with the lowest per-unit price – factor in the total cost of the order, including any setup fees or rush charges.”

“Doing the math upfront is critical when budgeting for bulk t-shirt printing. Consider your sales projections and plan for larger orders to maximise your savings on a per-shirt basis.”

“If you’re new to bulk t-shirt printing, I’d recommend starting with a smaller test run to get a better sense of the actual costs. This will help you refine your pricing and profit margins moving forward.”

Knowing how much bulk t-shirt printing costs and why helps you make smart, profitable decisions. Quantity, fabric, print method, colours, and lead times all influence your final price.

Don’t fixate on just the cheapest per-shirt cost. Think bigger: consider total spend, supplier reliability, and the quality your customers expect. With the right planning, you can keep costs down while producing premium results.

Find out more about T-Shirt Printing with Teesh.

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