How to Order Custom Merch Without Overpaying for Minimums
You've got the design, the brand, and the event date circled on the calendar. Then the quote comes back with a minimum of 48 pieces, and suddenly you're wondering whether you need 48 shirts or just don't want to pay for them.
Minimums are one of the most confusing parts of ordering custom merch. Once you understand why they exist, they get much easier to work around. Here's how to keep your costs in check without sacrificing quality.
Why Minimums Exist in the First Place
Most minimums come down to setup. Depending on the print method, a shop may need to prepare screens, burn your artwork, mix inks, or program a machine before the first item is ever printed. That work costs the same whether you order 12 pieces or 120, so shops set a minimum to make the job worthwhile.
Knowing this changes how you shop. The goal isn't to dodge minimums entirely. It's to choose options where the setup cost isn't driving your price.
1. Match the Print Method to Your Quantity
This is the single biggest lever you have.
Screen printing is cost-effective at larger quantities because the setup cost gets spread across many pieces. It's often not the best fit for small runs.
Heat transfer and DTF (direct-to-film) generally work better for smaller orders and multi-color designs, since they don't require a separate screen for each color.
Embroidery works well for polos, hats, and jackets, but complex or large designs can raise the price quickly.
If you only need a small batch, ask what method is being quoted and whether another option would fit better.
2. Simplify the Design
Every extra color, placement, or fine detail can add cost, especially in screen printing. Before you finalize artwork, ask yourself:
Can this design work in one or two colors instead of five?
Do I need a front print and a back print, or is one placement enough?
Will very small text or thin lines hold up on the fabric?
A simpler design is often more legible and looks more professional, and it keeps your quote down.
3. Limit Your Styles and Colors
A minimum often applies per design, and sometimes per garment color. Ordering 12 shirts in four colors is a very different job than ordering 48 in one. If you're working with a small budget, pick one core garment in one color and add variety later once you know what sells.
4. Order Once, Not Three Times
Ordering in several small batches usually costs more than one planned order, since you're paying setup and shipping repeatedly. If you know you'll need merch for a launch, an event, and a holiday push, ask for a quote on the combined quantity. Many shops offer price breaks as quantities go up, so it's worth asking where those tiers start.
5. Plan Ahead to Avoid Rush Fees
Tight deadlines are an easy way to overpay. Rush production, expedited shipping, and last-minute blank sourcing all add cost. Build in extra time, especially before holidays, when print shops fill up quickly.
6. Use Pre-Orders to Set Your Quantity
If you're selling merch instead of giving it away, you don't have to guess. Open pre-orders first, then place your order based on real demand. This lowers your risk and keeps you from sitting on inventory you can't move.
7. Ask What's Included in the Quote
Two quotes that look far apart may not be comparing the same thing. Before you decide, ask:
Is there a separate setup or art fee?
Are the blanks (the shirts themselves) included in the price?
What's the shipping or pickup cost?
What happens if I need to reorder later?
A slightly higher quote that includes everything can be cheaper than a low quote with add-ons.
The Bottom Line
Minimums aren't a penalty. They reflect real production costs, and you have more control over them than it might seem. Choose the right print method, keep the design focused, and order with a plan, and you can get quality merch that fits your budget.
Not sure what would work best for your project? Request a quote and tell us your quantity, timeline, and design, and we'll help you find the right fit.