Bulk Screen Printing Cost Explained: What Customers Should Know Before Ordering

If you’re planning to order custom shirts for a business, event, team, or promotion, one of the first questions that comes to mind is usually about price. More specifically, customers want a clear understanding of bulk screen printing cost before committing to an order.

This question comes up every day in screen print shops—and for good reason. Pricing can vary based on several factors, and without clear guidance, it’s easy to feel confused or unsure. In this article, we’ll break down exactly what affects bulk screen printing cost, why bulk orders save money, and how you can plan your order wisely.

What Is Bulk Screen Printing?

Bulk screen printing refers to printing the same design on a large quantity of garments—typically 24 shirts or more—using traditional screen printing methods. Each color in the design requires its own screen, which is why setup is one of the main cost factors.

Because the setup work is done once and reused across many shirts, bulk screen printing cost per shirt decreases as the quantity increases. This makes screen printing one of the most cost-effective options for large orders.

Why Bulk Orders Cost Less Per Shirt

One of the biggest advantages of bulk orders is efficiency. Screen printing involves preparation time—burning screens, setting up presses, and test prints. These steps cost the same whether you print 24 shirts or 500 shirts.

That’s why bulk screen printing cost is structured around volume. The more shirts you order, the more that setup cost is spread out, resulting in a lower price per piece.

Example:

• 24 shirts: higher cost per shirt

• 100 shirts: moderate cost per shirt

• 500 shirts: lowest cost per shirt

This pricing model rewards customers who plan ahead and order in larger quantities.

Main Factors That Affect Bulk Screen Printing Cost

Understanding what goes into pricing helps eliminate surprises. Here are the most important factors that determine bulk screen printing cost:

1. Quantity Ordered

This is the biggest pricing driver. Higher quantities = lower cost per shirt.

2. Number of Ink Colors

Each color requires a separate screen.

• 1–2 color designs are most affordable

• 4–6 color designs increase cost due to setup and labor

3. Print Locations

Printing on:

• Front only = lowest cost

• Front + back or sleeves = higher cost

4. Shirt Type and Quality

Blank garment pricing varies:

• Basic cotton tees cost less

• Performance, heavyweight, or premium brands cost more

5. Ink Type

Specialty inks (metallic, puff, glow, discharge) can raise bulk screen printing cost compared to standard plastisol ink.

Average Bulk Screen Printing Cost (General Range)

While prices vary by shop and region, here’s a realistic general range:

These estimates assume a basic shirt and a 1–2 color print. Complex designs or premium garments will affect the final bulk screen printing cost.

Why Screen Printing Is Better Than Other Printing Methods for Bulk Orders

Customers often compare screen printing to DTG (direct-to-garment) or heat transfer printing. For bulk orders, screen printing usually wins.

Screen printing advantages:

• Lower bulk screen printing cost at high volumes

• More durable prints

• Better color vibrancy

• Consistent results across hundreds of shirts

DTG may work for small orders, but once you move into bulk quantities, screen printing is typically the most economical choice.

How to Reduce Your Bulk Screen Printing Cost

Want to keep pricing as low as possible? Here are proven tips:

• Choose fewer ink colors

• Print only one location if possible

• Order higher quantities to hit better price breaks

• Select standard shirt styles

• Finalize artwork before production to avoid revisions

Small decisions can significantly impact your final bulk screen printing cost.

Frequently Asked Questions About Bulk Screen Printing Cost

1. What is the minimum order for bulk screen printing?

Most shops consider 24 shirts the minimum for bulk pricing.

2. Does bulk screen printing cost include setup fees?

Some shops include setup in the per-shirt price, while others list it separately. Always ask for clarity.

3. Is screen printing cheaper than DTG for bulk orders?

Yes. For larger quantities, bulk screen printing cost is almost always lower than DTG.

4. Do more colors drastically increase the price?

Each additional color increases setup and labor, which raises the total cost.

5. Are there hidden fees in bulk orders?

Reputable shops are transparent. Ask about setup, rush fees, and specialty inks.

6. How early should I place a bulk order?

Ordering 2–3 weeks in advance can help avoid rush fees and keep bulk screen printing cost lower.

Final Thoughts

Understanding bulk screen printing cost helps you budget accurately and make smarter decisions when ordering custom shirts. While pricing depends on several factors, ordering in larger quantities with simple designs is the most effective way to keep costs low.

If you’re planning a bulk order, working with a professional screen printer who explains pricing clearly can save you time, money, and stress.