Best Apparel Printing Method for Small Orders — What to Use When You Need Just a Few Shirts
Small orders — fewer than 36 pieces — are a common situation where people aren’t sure which print method to use. The answer matters: the wrong method on a small order either costs too much or produces a result that doesn’t meet expectations. Here’s a straightforward guide.
Main Street Shirt Company produces screen printing, DTF printing, and embroidery in-house in Illinois. We recommend the right method for your order size — not the one with the highest margin.
The Simple Answer: DTF for Small Orders
For orders of fewer than 36 pieces, DTF (Direct-to-Film) printing is the right choice. Here’s why:
- No minimum order quantity — even a single shirt
- No screen setup cost — pricing is based on print area and quantity
- Full color at no additional cost per color
- Works on all fabric types including polyester and performance fabric
- Individual pieces can each have a unique design, name, or number
Screen printing, by contrast, requires a minimum order of 36 pieces to recover the setup cost of making screens. On a 4-shirt run, screen printing is economically impractical. DTF is not.
What Happens at 36 Pieces and Above?
At 36 pieces, screen printing becomes available and the right choice depends on design complexity:
- Simple design with 1–4 colors, 36+ pieces: Screen printing is likely more cost-effective
- Full-color or photographic design: DTF may still be the better choice — ask for quotes on both
- Individual names on each piece, any quantity: DTF is the right choice regardless of quantity
- Performance/polyester garments: DTF avoids dye migration issues, so it’s preferred regardless of quantity
If you’re right around the 36-piece mark and aren’t sure, contact us with your artwork and we’ll quote both methods so you can compare directly.
What About Embroidery for Small Orders?
Embroidery is practical for small orders on caps, polos, and jackets because the main cost driver is stitch count, not quantity. There is no per-piece setup cost that scales with quantity in the same way as screen printing. A one-piece embroidered polo or cap is economically viable — the digitizing fee is a one-time cost that applies whether you order 1 item or 100.
For small orders of embroidered caps or branded polos, embroidery is a perfectly practical choice.
Can You Print One Shirt?
Yes — with DTF printing. There is no minimum for DTF. One shirt is a completely normal order. We produce single-piece DTF orders for customers who need a specific item, a gift, a sample, or a one-off personalized piece.
We do not screen print single shirts because the economics of screen printing make it impractical at that quantity.
What Is the Cheapest Way to Print a Small Number of Shirts?
For 1–35 pieces: DTF printing. It’s the only print method that is economically practical below our 36-piece screen printing minimum without compromising quality.
Keep in mind: “cheapest” includes the blank garment cost, not just the print. A cheap blank + DTF print is still a lower total cost than a premium blank + screen printing. Tell us your total budget and we’ll work backwards to find the best combination.
Summary: Print Method by Order Size
| Order Size | Recommended Method | Notes |
|---|---|---|
| 1 piece | DTF | Only practical option |
| 2–35 pieces | DTF | No minimums, no setup cost |
| 36+ pieces, 1–4 colors | Screen Printing | Setup cost now efficient |
| 36+ pieces, full-color design | DTF or Screen Printing | Get quotes on both |
| Any quantity, individual names | DTF | Each piece can be unique |
| Caps and beanies | Embroidery | Any quantity; standard for headwear |
| Polos and jackets | Embroidery | Professional look; practical even at 1 piece |
Related resources:
Ready to order? Contact us at info@mainstreetshirtcompany.com with your quantity, artwork, and deadline.