"Custom shirts" covers a dozen different jobs, and the right supplier for one is the wrong supplier for another. Twelve shirts for a stag do, one shirt with a private joke on it, and 200 shirts for a company event are three completely different problems. This guide explains how to tell them apart.
The four printing methods, and when each one wins
Direct-to-garment (DTG)
An inkjet printer sprays water-based ink directly into the fabric fibres, then heat-cures it. Unlimited colours, photographic detail, soft finish that does not crack.
Wins when: you want 1–20 shirts, or your design is detailed or multi-coloured. Cost per shirt stays flat regardless of quantity.
Loses when: you need hundreds. There is no bulk saving.
Screen printing
A separate stencil is burned for each colour, then ink is pushed through it. The traditional method.
Wins when: you need 25+ shirts of a simple one- or two-colour design. Cost per shirt drops sharply with volume, and the ink sits denser and brighter than DTG on dark fabric.
Loses when: you want a handful, or the artwork has gradients or photographic detail. Setup costs make small runs uneconomical, which is why most screen printers quote a 12–24 shirt minimum.
Heat transfer vinyl (HTV)
A design is cut from coloured vinyl and pressed onto the fabric.
Wins when: you need names and numbers, or simple bold text. Sports teams use it for a reason.
Loses when: the design is complex. Vinyl sits on top of the fabric rather than in it, so it is less breathable and can peel over years of washing.
Embroidery
Thread stitched directly into the garment.
Wins when: you want a premium, durable finish on polos, caps or workwear. It outlasts every printing method.
Loses when: the design is large or detailed, or the budget is tight. Stitch count drives cost, and fine detail is impossible.
Which one do you actually need?
| Your situation | Best method |
|---|---|
| 1–5 shirts, detailed design | DTG / print on demand |
| 25+ shirts, simple logo | Screen printing |
| Team names and numbers | Heat transfer vinyl |
| Company polos or caps | Embroidery |
| You have no design yet | AI generation + DTG |
What custom shirts actually cost
Rough guide, per shirt, printed one side:
- 1 shirt, DTG: $15–30
- 12 shirts, screen printed: $12–20 each, plus setup
- 100 shirts, screen printed: $5–10 each
- Embroidered polo: $20–40
Watch for costs quoted separately: setup or screen fees, artwork fees, rush fees, and shipping. A low headline price with three add-ons often beats a higher all-in price only on paper.
Minimum order quantities
The single most useful question to ask a supplier. Screen printers typically want 12–24 shirts. Print-on-demand services have no minimum at all, because nothing is produced until someone orders it. If you want one shirt, you need a print-on-demand supplier — a traditional printer either cannot help or will charge you as if you ordered twelve.
Turnaround: be honest with yourself about the deadline
This is where people get caught out. Three separate clocks run:
- Artwork approval — hours to days, depending on how ready your design is
- Production — typically 3–7 working days
- Delivery — anywhere from 2 days to 4 weeks depending on where it ships from
If you need shirts inside a week, use a domestic printer offering rush service and expect to pay for it. If your deadline is a month out, you have every option available and can optimise for cost or design quality instead.
Getting the design right
Four rules that apply regardless of who prints it:
- One clear focal subject. Busy designs turn to noise at chest size.
- High contrast against the garment colour. Light artwork on a dark shirt needs a white underbase; check your printer includes it.
- Text large enough to read at arm's length. If you are squinting on screen, it is unreadable on fabric.
- Supply artwork at 300 DPI, or use a supplier who generates print-ready files for you.
Sizing when you are ordering for other people
Most custom shirts are printed on unisex blanks, which are cut on a men's block. Anyone used to women's sizing will find the same nominal size roomier than expected. Rather than guessing, measure a shirt the person already wears: lay it flat, measure armpit to armpit, double it, and compare against the supplier's chart. Our unisex t-shirt size guide covers this in detail.
Where Wearlie fits — and where it does not
We are a print-on-demand service with one unusual feature: you do not need a design. You describe what you want in plain English, our AI generates print-ready artwork, and we print it on a t-shirt, hoodie, sweatshirt or cap.
Use us if you want 1–10 shirts, you have an idea but not a design file, and your deadline is three or more weeks away. Printed tees start at $19.99 with no minimum, no design fee, no setup fee, and free worldwide shipping.
Do not use us if you need 50 shirts for an event next Friday, or you need a specific corporate logo reproduced exactly. A local screen printer will serve you better and cost less. We would rather tell you that than take an order we are wrong for.
If we are a fit, start at custom shirts and t-shirts, or browse custom hoodies, custom sweatshirts and custom caps.
Frequently asked questions
What is the cheapest way to make custom shirts?
Screen printing at volume — roughly $5–10 per shirt at 100 units. For small quantities, print on demand is cheaper overall because there is no setup fee and no need to buy shirts you do not want.
Can I order just one custom shirt?
Yes, from a print-on-demand supplier. Traditional screen printers usually require 12–24 because of stencil setup costs.
How long do custom shirts take to make?
Production is typically 3–7 working days, plus delivery. Domestic rush services can manage 1–3 days; international print-on-demand can take 2–4 weeks in total.
What is the best printing method for a detailed design?
Direct-to-garment. It handles unlimited colours, gradients and photographic detail, none of which screen printing manages well.
Do custom printed shirts fade in the wash?
Properly cured DTG prints survive dozens of washes. Turn the garment inside out, wash cold, tumble dry low, and never iron directly over the print.
What if I do not have a design?
Either hire a designer, use a template tool, or describe your idea to an AI generator that produces print-ready artwork. The last option is what Wearlie does.