“In the US, average costs range from $5 to $15 per shirt for bulk orders (50+ units). However, traditional shops often add a $130 setup fee, whereas The Apparel Factory offers FREE setup and FREE shipping across the USA, significantly lowering the total cost per unit.”

If you are searching for how much screen printing costs in the US in 2026, the answer depends on four key factors: setup fees, order quantity, garment quality, and shipping logistics. While the traditional US market still relies on complex pricing models, The Apparel Factory has disrupted the industry by offering transparent, all-inclusive pricing.

Whether you are a startup launching a streetwear brand, a corporate manager ordering uniforms, or an event organizer, this guide will dissect every penny spent on screen printing. At The Apparel Factory, we believe that a well-informed customer is our best partner. This guide breaks down exactly what you should pay and how to maximize your ROI.

What Is Screen Printing & Why Is It Still King in 2026?

Screen printing remains the most durable and cost-effective method for high-volume custom apparel. By using a mesh screen to apply ink directly onto fabric, it produces vibrant, long-lasting results that digital methods like DTG cannot match in bulk. This durability is why it remains the industry standard, supported by the latest advancements in the printing industry regarding ink longevity and automated production.

Top Use Cases for Screen Printing in the USA:

• Corporate Branding: Professional uniforms and staff shirts.
• Retail & Resale: High-quality merch for clothing brands.
• Event Marketing: Bulk t-shirts for trade shows and marathons.

The Anatomy of a Screen Printing Quote

Before diving into the numbers, it is essential to understand that screen printing is an analogue, labour-intensive craft. Unlike a digital printer that simply sprays ink, screen printing involves several technical steps that dictate the final invoice.

The Pre-Production Phase

Every job begins with art separation. If your logo has three colors, a graphic technician must separate those into three individual black-and-white films. These films are then used to “burn” images onto mesh screens coated with light-sensitive emulsion. This is why “Setup Fees” exist. Even if you only want one shirt, the hours of prep work remain the same.

The Production Phase

Once the screens are ready, they are mounted onto a press. In 2026, most high-volume shops use automatic presses, but manual presses are still used for precision small-batch work. Each color is squeegeed through the mesh onto the fabric, followed by a trip through a conveyor dryer at temperatures around 320°F to “cure” the ink.

Cost of Screen Printing in the US

In 2026, most US buyers are surprised by “hidden” charges. Here is how the market average compares to the value-driven model at The Apparel Factory.

How Order Quantity Drastically Reduces Your Price

• 1–12 Shirts: Premium pricing due to labor-intensive setup.
• 50 Shirts: The “Sweet Spot” where costs drop by nearly 50%.
• 150–300 Shirts: Ideal for mid-sized events and local brands.
• 500+ Shirts: Wholesale-level pricing for maximum profitability.

Key Factors Influencing Your Custom Apparel Budget

• Ink Colors: Each color requires a new screen. A 1-color white print on a black shirt is the most budget-friendly. To maintain brand integrity across multiple colors, we utilize the standardized Pantone Matching System (PMS) to ensure your logo colors are exact every time.
• Garment Choice: Premium tri-blends or heavyweight hoodies cost more than standard 100% cotton tees.
• Print Placement: Front-only designs are more affordable than Front + Back + Sleeve combinations.
• Sustainability: In 2026, eco-friendly water-based inks are in high demand and may carry a slight premium but offer a better “hand-feel.” Many of our premium fabric options also adhere to certified organic and sustainable textile standards, ensuring your brand remains eco-conscious.

Screen Printing vs. Other Methods: Which is Best for You?

• Screen Printing: Winner for Bulk. Best durability and lowest per-unit cost for 24+ pieces.
• DTG (Direct to Garment): Best for highly detailed photos and very small orders (1-10 pieces).
• Heat Transfer: Good for names and numbers on jerseys, but lacks the longevity of screen printing.

Why The Apparel Factory is the Top Choice for US Businesses?

We have optimized our 2026 service model to solve the biggest pain points for American customers:

• Zero Setup Fees: We waive the industry-standard $130 fee, making us the most competitive choice for startups.
• Transparent Bulk Discounts: Higher quantities reduce both the printing and the garment cost.
• Free Nationwide Shipping: No matter where you are in the US, the price you see is the price you pay.
• Fast Turnaround: Need it yesterday? We offer expedited production for tight deadlines.

Not Sure Which Garment to Choose?

Let our 2026 apparel experts guide you through the best ink-to-fabric combinations for your specific needs. 📞 TALK TO A PRINTING EXPERT