Startup Costs for Custom T-Shirt Printing and How to Minimize Them

Starting a custom t-shirt business can be profitable, but your upfront investment will vary depending on your printing method. This guide breaks down the true startup costs, recommended blank shirts, and most importantly how to minimize costs for each printing style without sacrificing quality. These are the startup costs for custom t-shirt printing methods.

1. Screen Printing: Startup Costs for Custom T-Shirt Printing

Best for:
Bulk orders, bright spot colors, long-lasting designs

Estimated Startup Costs

• Manual screen printing press (1- to 4-color): $250–$800

• Flash dryer: $300–$1,200

• Conveyor dryer (optional for scaling): $1,500+

• Screens and frames: $25–$40 each

• Squeegees: $10–$30 each

• Emulsion and scoop coater: $50–$100

• Exposure unit or DIY exposure setup: $200–$500

• Plastisol inks: $100–$200

• Cleanup chemicals: $50–$100

• Adhesive spray or platen tape: $15–$30

• Tools and accessories (gloves, spatulas, etc.): $50–$75

Total Startup Range: $1,200 – $3,500

Recommended Wholesale Blanks

• Gildan 5000 Heavy Cotton – Affordable, great ink absorption

• Bella+Canvas 3001 – Premium airlume combed ring-spun cotton for higher resale value (What is combed ringspun cotton?)

How to Minimize Costs

• Start with fewer screens and colors — Offer simple 1 or 2 color designs to avoid buying extra screens.

• DIY your exposure unit — Use a 500-watt halogen work light and a blacked-out box instead of a professional exposure unit.

• Buy used equipment — Craigslist, Facebook Marketplace, or local print shops often sell lightly used presses and dryers.

• Mix your own ink colors — Purchase basic CMYK and white inks and mix custom colors instead of buying every shade.

2. Direct-to-Garment (DTG)

Best for:
Print-on-demand, photo-quality detail, small orders

Estimated Startup Costs

• DTG printer: $5,000–$18,000

• Heat press: $200–$800

• Pretreatment machine (optional): $2,000+

• Pretreatment solution: $50–$100 per gallon

• DTG ink (CMYK + white): $400–$1,000

• Maintenance tools and cleaning fluid: $100–$200

• RIP software: Usually included

Total Startup Range: $7,000 – $20,000

Recommended Wholesale Blank Shirts

• Bella+Canvas 3001 – Excellent for DTG because of tight weave

• Next Level 3600 – Soft, durable, optimized for digital printing

How to Minimize Costs

• Use pretreat by hand — Start with a handheld sprayer and foam roller to avoid buying a pretreat machine.

• Buy refurbished equipment — Some companies sell factory-refurbished DTG printers at a discount with a warranty.

• Keep a maintenance schedule — Ink clogs are costly. Regular cleaning extends the life of your printer and saves on repairs.

• Choose lighter shirt colors — Printing on white or light colors saves expensive white ink.

3. Direct-to-Film (DTF)

Top 10 Questions About DTF Printing

Best for:
Small-batch or on-demand printing, full-color graphics

Estimated Startup Costs

• DTF printer: $3,000–$6,000

• Heat press: $200–$800

• PET film rolls: $100–$200

• DTF inks (CMYK + white): $300–$600

• TPU adhesive powder: $50–$100

• Curing oven (optional): $500–$1,000

• Cleaning/maintenance supplies: $50–$100

Total Startup Range: $3,700 – $7,800

Recommended Wholesale Shirts

• Gildan 64000 Softstyle – Smooth surface, good for transfers

• Jerzees 29MR Dri-Power – Works well with poly blends and budgets

How to Minimize Costs

• Buy a converted DTF printer — Many converted Epson printers work well and cost half as much as commercial models.

• Use a heat press instead of a curing oven — If you’re not printing in high volume, a press can cure film effectively.

• Purchase film and powder in bulk — Look for starter bundle kits to reduce the price per print.

• Print gang sheets — Print multiple transfers per sheet to reduce wasted film.

4. Heat Transfer Vinyl (HTV)

What Are The Differences Between HTV And DTF Transfers?

Best for:
Custom names, low-volume personalized work, hobby businesses

Estimated Startup Costs

• Vinyl cutter: $250–$1,200

• Heat press: $300–$800

• HTV rolls (by color): $10–$50 each

• Weeding tools: $10–$30

• Heat transfer tape or Teflon sheets: $15–$30

• Design software: Often free or included

Total Startup Range: $600 – $2,000

Recommended Bulk Shirts

• Gildan 2000 Ultra Cotton – Reliable and thick, great for HTV

• Hanes 5250 Authentic – Smooth surface for crisp vinyl adhesion

How to Minimize Costs

• Start with a Cricut or Silhouette cutter — Affordable options perfect for small runs or beginners.

• Buy multi-color vinyl packs — Cheaper than buying individual rolls if you offer multiple designs.

• Avoid intricate designs — They take longer to weed and increase production time.

• Batch cut and weed — Save time and reduce setup by prepping multiple orders at once.

5. Sublimation: Startup Costs for Custom T-shirt Printing

Best for:
Polyester apparel, athletic wear, all-over color designs

Estimated Startup Costs

• Sublimation printer: $500–$1,200

• Sublimation ink: $200–$400

• Sublimation paper: $20–$60

• Heat press: $300–$800

• Polyester T-shirts: $3–$6 each

• Teflon sheets and lint rollers: $10–$30

Total Startup Range: $1,000 – $2,500

Recommended Wholesale Blank Styles

• Team 365 TT11 Performance Tee – Lightweight and fully sublimation-ready

• Augusta Sportswear 790 – Great for moisture-wicking sportswear

How to Minimize Costs

• Use a converted Epson printer — Some inkjet printers can be converted to sublimation for under $300.

• Stick to basic light-colored polyester — Avoid premium blends or pre-treated fabrics if you’re just starting.

• Print smaller designs — Conserve paper and ink instead of starting with full-front or all-over prints.

• Buy blanks in bulk — Polyester blanks get cheaper when purchased by the case.

Here’s a great video from Hustle Ninjas on costs of t-shirt printing methods.

You don’t have to spend thousands to launch your very own t-shirt brand. By choosing the right method for your goals and budget, and by following these cost-cutting tips, you can get started faster and smarter. You want to minimize as much as possible the startup costs for custom t-shirt printing.

Recap of Methods & Cost-Saving Potential:

• Screen Printing: Best for bulk. DIY setups and used equipment reduce cost significantly.

• DTG: High startup, but refurb machines and hand pretreating can help cut the initial investment.

• DTF: Lower entry point than DTG with similar quality; gang sheets and converted printers save money.

• HTV: Best for beginners. Great low-cost entry with minimal tools.

• Sublimation: Affordable and vibrant, especially when using converted printers and bulk polyester blanks.

The startup costs for custom t-shirt printing can vary greatly between methods and brands but the important thing is that you get started with your business. Start small and low-cost if you have to but get out there and get creative!

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