The True Cost of Custom Apparel: What You're Really Paying For
1. The Garment Itself
(Not All Shirts Are Equal)
The blank shirt is the foundation of everything when it comes to custom apparel.
Prices vary depending on:
Fabric quality (cotton, blends, performance fabrics) Weight and durability Fit and feel Brand consistency
A £2 shirt and a £6 shirt may look similar at first glance, but they won't wear, wash, or feel the same. Better blank garments produce better custom apparel results - and get worn far more often, giving your brand longer-lasting exposure.
2. Artwork Setup & Design Prep
Before anything gets printed or stitched, your custom design needs to be properly prepared.
This can include:
Cleaning up artwork Converting files to print-ready formats Separating colours for screen printing Digitising artwork for embroidery
This skilled, behind-the-scenes work ensures your custom logo prints cleanly and accurately - not blurry, cracked, or distorted.
3. Screen Printing Setup (or Embroidery Digitising)
For Screen Printing
Each colour in your custom design requires:
A separate screen Coating, exposure, and setup time Press setup and test prints
For Embroidery
Your logo must be digitised into stitch paths that embroidery machines can read. Stitch count, density, and level of detail all affect custom embroidery production time and cost.
These setup steps happen before the first custom shirt is produced, which is why smaller branded apparel orders typically cost more per item.
4. Ink, Thread, and Materials
Quality materials make a noticeable difference in your finished custom merch.
You're paying for:
Professional-grade inks that won't fade or crack Thread that holds its colour and shape Specialty inks (metallics, puff, discharge, and more)
Cheaper materials may look fine initially, but they don't stand up to real-world wear and washing - a risk not worth taking with branded apparel.
5. Skilled Labour & Production Time
Custom apparel and branded merch isn't automated fast fashion.
It requires trained professionals to:
Set up screen printing presses or embroidery machines Align custom prints accurately Monitor quality throughout production Catch issues before they become costly mistakes
You're paying for craftsmanship - not just output.
6. Quality Control
(The Step You Don't See)
Every custom apparel order is checked for:
Proper placement Colour accuracy Ink or stitch consistency Overall appearance
Quality control prevents misprints, crooked logos, and wasted garments - saving you money, delays, and frustration on your branded clothing order.
7. Order Quantity & Price Breaks
Custom apparel and branded merch rewards planning.
Smaller orders cost more per piece due to setup time. Larger bulk orders spread setup costs across more items, reducing per-shirt pricing significantly
That's why ordering a few extra custom shirts upfront often costs less than placing a reorder later.
8. Equipment, Overhead & Expertise
Professional custom print shops invest heavily in:
Commercial screen printing presses and embroidery machines Regular maintenance and calibration Software, utilities, and workspace Ongoing training and experience
This investment is what separates professional custom apparel results from DIY or bargain-basement printing.
9. Customer Service & Guidance
A good custom apparel shop doesn't just print - they advise.
You're paying for help with:
Choosing the right blank garment for your branded merch Selecting the best print method - screen printing, DTF, or embroidery Avoiding costly mistakes Getting the best value for your custom apparel budget
That guidance alone can save more than it costs. Visit our FAQ's or send us a message if you have any questions and we will help you out!
10. Long-Term Value
(The Part People Forget)
The real cost question isn't: "How cheap is this shirt?"
It's: "How many times will it be worn?"
A well-made custom shirt or piece of branded apparel:
Gets worn again and again Represents your brand positively Acts as ongoing advertising for your business
Cheap custom merch gets ignored. Quality branded apparel gets noticed.
Final Thoughts
Custom apparel isn't an expense - it's an investment in your brand.
When you understand what goes into the cost, it becomes clear why professional screen printing and embroidery deliver better results, fewer headaches, and stronger brand impact for your custom merch.
If you're unsure where your budget should go, working with an experienced custom print shop like Print Stream Studio can help you get the most value from every shirt you order.
Written by Fletcher
Print Stream Studio