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WHY SCREEN PRINTING IS CHEAPER FOR BULK ORDERS

Why Screen Printing Is Cheaper for Bulk Orders

Why Does Screen Printing Cost Less Per Shirt in Bulk?

Screen printing offers significant cost savings for bulk t-shirt orders due to high initial setup costs like screen creation and ink preparation, which get spread across larger quantities, reducing the per-shirt price dramatically. For Brisbane businesses and events, this traditional method excels in producing vibrant, durable prints ideal for uniforms, teams, and promotions, outperforming DTG for volumes over 20-50 shirts. Economies of scale make it the go-to for orders of 60+ units, where costs can drop to as low as $5-15 per shirt depending on colors and quantity, ensuring long-lasting quality without fading after washes.

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Key Takeaways

  • High setup costs for small runs: Screen printing requires stencils/screens for each colour, which makes small orders expensive. Larger quantities help spread (amortise) these fixed setup costs.
  • Bulk lowers the per-shirt price: Bigger orders distribute setup fees across more shirts—for example, 100 shirts might add around $1 per shirt in setup, compared with around $10 per shirt on a 10-shirt run.
  • Most cost-effective at 20+ shirts: Screen printing is generally best value from about 20 shirts and works especially well for runs of roughly 50–300 units with simple designs (ideal for Brisbane teams and events).
  • Superior print durability: The thicker ink layer is hard-wearing and resists fading after repeated washing, making it great for workwear, sports uniforms, and merchandise.
  • Screen vs DTG for bulk: Screen printing typically wins on cost and longevity for larger runs, while DTG is often better for small orders because it has little to no setup.
  • Australian bulk pricing example: Some Brisbane printers (including those using JBS Wear garments) may quote around $14.50 + GST per shirt for a 300-unit, one-colour print with front and back placement.

Screen printing becomes cheaper for bulk orders because setup costs are spread across more shirts, reducing the cost per shirt as quantity increases.

This is why screen printing is widely used for clubs, events, uniforms, and large promotional orders.

How Screen Printing Pricing Works

Screen printing requires an initial setup process before production begins. This setup is necessary whether you print 20 shirts or 200 shirts.

Key setup elements include:

  • Preparing artwork for print
  • Creating screens for each ink colour
  • Setting up presses and inks
  • Test prints and alignment

These setup steps are largely fixed costs.

The Role of Economies of Scale

Once the setup is complete, printing additional shirts becomes much faster and more efficient.

This creates economies of scale, meaning:

  • The setup cost is divided across more units.
  • Labour time per shirt decreases.
  • Ink usage becomes more efficient.
  • The cost per shirt drops as quantity increases.

The more shirts you print, the lower the setup cost per shirt becomes.

A Simple Example

Imagine a screen printing setup costs the same whether you print:

  • 20 shirts
  • 100 shirts
  • 200 shirts

When that setup cost is spread across:

  • 20 shirts → higher cost per shirt
  • 100 shirts → much lower cost per shirt
  • 200 shirts → lowest cost per shirt

This is why bulk orders benefit the most from screen printing.

Real-World Bulk Pricing Examples

In real bulk orders:

  • Smaller runs may cost over $20 per shirt
  • Larger runs can drop to $14–$15 per shirt

These reductions are driven by quantity, not lower quality.

👉 You can see real pricing examples on the Pricing Page.

How Garment Choice Affects Bulk Savings

Garment cost also plays a role in bulk pricing.

  • Premium garments increase the base cost per shirt.
  • Value garments reduce the base cost per shirt.

When combined with bulk screen printing, choosing a value-focused garment can significantly increase your savings without affecting print quality.

Why Screen Printing Is Often Cheaper Than Other Methods at Scale

Compared to digital methods like DTG or DTF:

  • Screen printing rewards repetition
  • Digital printing charges apply per shirt
  • Screen printing becomes more efficient as volume increases

This is why screen printing is rarely the cheapest option for 1–5 shirts, but often the most economical choice for large runs.

When Screen Printing Is NOT the Cheapest Option

Screen printing may not be the best choice if:

  • You only need a small number of shirts
  • Each shirt has a different design
  • Your artwork contains photographs or gradients

In these cases, DTG or DTF printing may be more suitable.

Who Benefits Most from Bulk Screen Printing?

Screen printing is ideal for:

  • Sporting clubs and teams
  • Corporate uniforms
  • Schools and community groups
  • Event staff and volunteers
  • Promotional campaigns

Any order where the same design is printed repeatedly benefits from screen printing’s economies of scale.

Key Takeaway

Screen printing is cheaper for bulk orders because:

  • Setup costs are fixed
  • Efficiency increases with quantity
  • Cost per shirt drops as volume rises

When planned correctly, it offers one of the best value solutions for large custom t-shirt orders.

Explore Pricing & Next Steps

To see how bulk pricing changes with quantity:

If you’d like an accurate price for your order, request a personalised quote and we’ll recommend the most cost-effective option.

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