That quote you got back looks expensive? Before you panic, understand what's driving the number. Decoration—how your logo gets applied—is the second-biggest cost variable after base product price. And unlike product cost, decoration pricing isn't opaque.
Three factors dominate: color count, stitch count, and placement complexity. None of them are tricks.
Screen Printing: It's All About Color Count
Screen printing starts simple: one color, one pass through the press, minimal cost. Add a second color? New screen, new pass, extra labor. A third color? Repeat.
Most budget shirts cap at 1–3 colors on a single location (usually left chest or back). Here's the rough tier:
- 1 color: Base rate. Your starting point.
- 2 colors: +20–30% over one color.
- 3 colors: +40–50% over one color.
- 4+ colors: Pricing jumps significantly; many shops add per-color charges or steer you toward embroidery or direct-to-garment.
One wrinkle: if you're printing the same two-color design on 500 shirts, the per-unit cost for that second color drops because you're amortizing screen setup. Volume is your friend.
Placement Complexity: Size and Location Matter
A small left-chest logo on a Daily Driver Tee is the cheapest option. That's why it's the most common. Moving your design changes the price.
- Left chest (small): Standard. No premium.
- Large front print (6"+): Bigger screens, more ink, more labor. Expect +15–25%.
- Back placement: Usually the same as equivalent front, sometimes slightly higher on fitted garments.
- All-over or placement on multiple body parts: Per-location charges add up fast. A full-back print plus sleeves can 2–3x the decoration cost vs. left chest alone.
- Prints on seams or curved surfaces: Setup difficulty drives premiums. Shoulder prints or wrap-around designs cost more than flat panels.
The rule: simplicity wins. Left chest, small, one or two colors stays cheapest.
Embroidery: Cost Scales With Stitch Count
Embroidery quotes aren't based on the logo size—they're based on stitch count. More stitches = longer machine time = higher cost.
A detailed 500-stitch logo embroidered on the left chest of a Basecamp Hoodie will cost more than a 200-stitch simplified version of the same design. Complex logos with thin lines, gradients, or fine detail inflate stitch counts. Simple geometric logos with thick lines? Lower count, lower cost.
Most embroidery shops quote per 1,000 stitches or provide a price range tied to design complexity. One-cap embroidery (one location, one design) scales better than multi-location embroidery. A hat with embroidery on the front and back runs double or more the cost of front-only.
Embroidery also has MOQ (minimum order quantity) pressure—shops often require 12–25 pieces minimum, whereas screen printing can start lower. That's not a decoration-cost factor, but it affects your total spend.
Why Direct-to-Garment Breaks the Rules
Direct-to-garment (DTG) printing dodges most decoration-cost logic because it doesn't use screens or embroidery machines. The machine treats your digital file like an inkjet printer treats paper. Color count? Irrelevant. Placement complexity? No extra charge—as long as the design fits on the garment and isn't too close to seams.
DTG is ideal for full-color logos, photorealistic images, or one-off orders. But it costs more per unit than screen printing on large runs (100+). Think of DTG as the premium decorator for small batches and complex art; screen printing as the efficiency play for volume.
Placement and MOQ: The Hidden Multiplier
Minimum order quantities aren't technically a decoration cost, but they force your average cost up if you order fewer pieces. Screen printing at 50 units might carry a 25-piece MOQ per design. Embroidery often carries a 12-piece cap minimum. A 6-shirt order could require a surcharge or require you to hit the MOQ anyway.
If you're decorating only 10 Structured Six-Panels with a logo, your per-unit decoration cost will be higher than if you ordered 100—not because the decorator is being greedy, but because labor and setup are fixed costs spread across fewer units. Plan ahead and order what you'll actually use. Bulk orders and simple designs trump everything.
FAQ
Why does my quote jump so much when I add a third color?
Each color requires a separate screen and a separate pass through the press. Fixed setup cost per screen. At low volumes, that setup is a big per-unit hit. At 500+ units, the per-unit color charge shrinks because you're spreading that fixed cost across more shirts.
Is embroidery cheaper than screen printing?
Not always. Embroidery's per-unit cost depends on stitch count and your order size. Screen printing wins on large volume (100+ units) and simple designs. Embroidery wins on premium look and feel, small orders (if you hit the MOQ), and complex multicolor logos. Compare quotes for your specific design.
Can I reduce decoration cost by simplifying my logo?
Yes. Fewer colors = fewer screens = lower cost for screen printing. Fewer or thicker lines = lower stitch count = lower cost for embroidery. Direct-to-garment ignores color count, so simplification doesn't save you there. Understand which method you're using, then optimize for it.
What's the cheapest promo product to decorate?
Cotton tees with left-chest screen printing, 1–2 colors. Pens and drinkware also accept low-cost imprinting methods. Avoid all-over prints, complex embroidery, and multiple placement options if you want to stay lean on decoration spend.