Screen Printing in DFW: What It Costs and When to Use It

Screen printing is still the workhorse of custom apparel for a reason: it lays down a thick, durable ink film at a per-shirt cost that nothing else can touch at volume. But it is also the method people most often choose for the wrong order. This guide explains how screen printing pricing actually works in DFW, when it is the right call, and how to set up artwork that prints crisp.

How screen printing pricing works

Three numbers determine your invoice: setup fees, blank cost, and per-shirt print cost.

Setup fees

Each ink color requires its own screen, and each screen has to be burned, aligned on the press, and reclaimed afterward. That setup is a fixed cost regardless of whether you print 24 shirts or 240. A four-color front plus a one-color back is five screens of setup. This is why screen printing makes more sense at higher quantities.

Blank cost

Cotton tees (Gildan 5000, Port & Co. PC54, Bella+Canvas 3001) run roughly $4–$10 each in DFW depending on style and color. Hoodies, performance fabrics, and premium ringspun fabrics scale up from there.

Per-shirt print cost

Once setup is done, each additional shirt is fast. Per-shirt print cost typically falls between $1.50 and $5 depending on color count and print location. Adding a second print location (front and back, or front and sleeve) adds a per-shirt cost, not just a setup fee.

When to choose screen printing

• 24+ shirts with the same artwork
• 1–4 ink colors in the design
• Cotton or cotton-blend tees, hoodies, sweatshirts
• Designs that need a thick, vivid ink lay with hand-feel character
• Long-life merch that needs to survive years of industrial laundering

When to choose a different method

• Under 24 shirts or one-offs → use DTF transfers instead.
• Full-color photographic logos or gradients → DTF prints those cleanly without separating colors.
• Polos, caps, jackets, dress shirts → embroidery looks more professional.
• Individual names and numbers → DTF or embroidery handle personalization without per-name screens.

How to design artwork that prints crisp

Send vector files

Submit logos as .ai, .eps, or layered .pdf in vector form. Vector lines stay sharp at any size and let us separate colors cleanly. PNG and JPG files almost always need to be redrawn for production.

Choose colors with care

Each color is a separate screen, separate ink mix, and separate registration on press. Two carefully chosen colors often look better and cost less than four mediocre ones. If you need exact brand matching, send Pantone (PMS) codes.

Mind your minimum line weight

Lines thinner than 1 pt and type smaller than 6 pt can drop out during the burn. We will flag anything that risks falling off the screen, but designing with sturdy line weights from the start saves a round of revisions.

Keep contrast in mind on dark shirts

Printing on a black or navy shirt requires an under-base of white ink to make colors pop. That counts as an extra screen and is worth knowing during the design stage.

Industries that screen print the most

Screen printing is the default for the volume side of these programs:

• Event and promotional shirts for runs, festivals, and trade shows
• School spirit wear for student bodies, staff days, and booster fundraisers
• Church and nonprofit shirts for mission trips and community events
• Gym and fitness merch for member drops and finisher shirts

Request a screen printing quote or contact us and we will recommend the right setup for your order.