Direct Answer
Most screen printing orders require a minimum of 12 to 144 shirts because each color in the design requires setup time and preparation. Once the screens are prepared, printers can produce large quantities quickly, which is why screen printing becomes much cheaper as the order size increases. Minimums can increase when more colors are used in the design. For very small orders, digital methods like DTG or DTF printing are often better options.
Why Screen Printing Has Minimum Orders
Screen printing requires preparation before production begins. Each color in the design requires a separate screen, and the printer must set up the press and mix inks before printing starts. This setup process takes time, so producing only one or two shirts would make the cost per item extremely high. By printing multiple shirts at once, the setup cost is spread across the entire order.
Typical Screen Printing Minimums
| Order Type | Typical Minimum |
|---|---|
| Small print shops | 12 shirts |
| Most commercial printers | 24 shirts |
| Large production runs | 50+ shirts |
The exact minimum may vary depending on the print shop and design complexity. A+ Images doesn’t officially have a minimum, but setup charges will apply if less than 12 shirts are ordered.
When Screen Printing Makes the Most Sense
Screen printing is usually the best option when:
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ordering 12 or more shirts
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printing simple designs
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producing bulk event apparel
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creating company uniforms
For larger orders, screen printing often produces the lowest cost per shirt.
What If You Only Need One Shirt?
If you only need one or a few shirts, digital printing methods are usually better.
DTG Printing
DTG printing applies ink directly to the garment and works well for detailed designs.
DTF Printing
DTF printing transfers designs using heat and works on many types of fabric.
These methods allow printers to produce small orders without extensive setup.
Why Larger Orders Cost Less
Printing costs decrease as order quantities increase because the setup cost is distributed across more garments.
Example:
| Quantity | Estimated Cost Per Shirt |
|---|---|
| 1–5 shirts | $25–$35 |
| 12–24 shirts | $12–$20 |
| 50+ shirts | $8–$12 |
These numbers vary based on garment quality and design complexity.
Final Thoughts
Screen printing remains one of the most affordable and durable methods for decorating custom apparel when producing larger quantities. Understanding minimum order requirements helps businesses and organizations choose the most cost-effective printing method for their needs.
For smaller orders, digital printing options such as DTG or DTF may provide better flexibility.