How Many Shirts Do You Need? Custom Apparel Minimum Orders Explained
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Minimum orders are the number-one question we get from first-time custom apparel buyers. Most shops bury their minimums or quote a generic "12 pieces" without explaining why. This guide gives you the real minimums by decoration method, why those numbers exist, and how to work around them.
Quick answer
- Screen printing: cost-effective starting at 24 pieces. Below that, setup fees overwhelm the per-shirt savings.
- DTF (direct-to-film): 1 piece. No minimum at all.
- Embroidery: 6–12 pieces is the practical floor; we can go lower for personalized items.
- Promotional products (cups, bags, pens, etc.): usually 24–100 pieces depending on item.
Why screen printing has a minimum
Each ink color requires its own screen, ink mix, and press setup. That fixed cost is the same whether you print 6 shirts or 600. At low quantities you are essentially paying for the setup with very few shirts to spread it across. By around 24 pieces, the math starts to favor screen printing; by 100+, it is far cheaper than any other method.
If you only need 6 shirts and your heart is set on screen printing, we will still quote it — but in almost every case we recommend DTF instead and save you money.
Why DTF has no minimum
DTF transfers print onto film with no per-color setup. The fixed cost per order is basically zero, so a 1-piece order and a 100-piece order have the same per-shirt math. This is what makes DTF the right call for new-hire onboarding, replacement uniforms, and event-day reorders. Read the DTF printing guide for details.
Why embroidery has a soft minimum
Embroidery has a one-time digitizing fee (converting your logo into stitch instructions) and a per-piece run cost. The digitizing fee is amortized across the order, so very small runs feel expensive per piece. Once you cross about 12 pieces, the per-shirt cost stabilizes. We can run smaller orders — especially for personalized name embroidery — just know the per-piece cost looks higher.
How to work around minimums
1. Combine methods in one purchase order
Need 6 staff polos and 50 event tees? We can embroider the polos and screen-print the tees in the same job, with one invoice and one delivery date.
2. Use DTF for the short side of the order
If you only have 8 shirts to print but want screen-print quality, DTF will get you almost the same look without the screen-printing setup math.
3. Stockpile blanks for the year
If you reorder shirts in small batches, ordering blanks in larger quantities once a year and printing in smaller batches as needed often beats the all-in-one minimum game.
4. Plan reorders against staffing cycles
Restaurants and trades who hire continuously do best with a hybrid: print a batch of generic uniforms upfront, then DTF individual names for new hires as they start. We can keep your roster, art, and sizing on file so the reorder is one email.
Minimums by product type
| Product | Method | Minimum |
|---|---|---|
| Cotton T-shirts | Screen print | 24 |
| Cotton T-shirts | DTF | 1 |
| Performance T-shirts | DTF | 1 |
| Polos | Embroidery | 6–12 |
| Hoodies / Sweatshirts | Screen print | 24 |
| Caps and beanies | Embroidery | 12–24 |
| Aprons | Embroidery or DTF | 1–12 |
| Tote bags | Screen print | 24 |
| Drink tumblers | Laser or print | 24–48 |
Frequently asked questions
What is the smallest order you will take?
Why do shops list a 12-piece minimum if DTF has no minimum?
Will my per-shirt price drop a lot if I add more?
Do you offer reorder pricing?
Get a quote for any quantity or contact us and we will recommend the right method.