Table of Contents
- What You'll Need Before You Order
- How to Order Custom Shirts: The Step-by-Step Process
- Screen Printing vs Digital Printing: Which Is Right for Your Design?
- T-Shirt Design Tips for Printing That Actually Work
- Understanding Bulk Custom Shirt Pricing
- Choosing the Right Fabric and Garment Weight
- Common Design Mistakes and How to Avoid Them
- Turnaround Times, Shipping, and Rush Orders
- Sustainability and Eco-Friendly Inks
- Conclusion
- Frequently Asked Questions
Last Updated: September 11, 2026
What You'll Need Before You Order
Getting your artwork print-ready before you start is the single biggest time-saver when you learn how to order custom shirts. Most delays happen because a file is too low-resolution or the wrong format, so sort this out first.
Here's your pre-order checklist:
- Vector file (.AI.EPS.PDF) or a high-resolution PNG at 300 DPI minimum
- Exact text, spelling and font choices confirmed
- Print placement decided: front, back, sleeve or a combination
- Rough quantity, including spares for sizing swaps
- Deadline, and whether you need a rush turnaround
The fix is simple: check your file at full size before you upload, not after.
How to Order Custom Shirts: The Step-by-Step Process
The process breaks into three stages: choose your garment and fit, upload artwork for a mockup, then confirm quantities and delivery. Each stage takes minutes if your files are ready, which is why the checklist above matters so much.
Step 1: Choose Your Garment Style and Fit
Start with the blank, not the design. A heavyweight cotton tee prints differently from a lightweight blend, and fit varies between cuts.
- Classic fit: roomier through the body, good for group orders
- Fitted or slim: closer cut, popular for personal shirts
- Heavyweight cotton: holds shape and suits bold prints
- Blends: softer drape, better for large solid colour blocks
Order one sample if you're unsure. It costs less than reprinting a whole run.
Step 2: Upload Your Artwork and Get a Mockup
Upload your file through the design tool and request a mockup preview before you commit. The mockup shows exactly where the print lands on the garment and how the colours will read against the fabric.
Check three things: print size relative to the chest, placement height, and colour matching against the shirt colour. A design that looks sharp on a white background can disappear on a dark garment.
Step 3: Confirm Your Order and Delivery Details
Confirm quantity, sizes, print placement and shipping address in one pass. Double-check the size breakdown, because custom-printed garments usually can't be resized after production starts.
Add your deadline in the notes. If you need it faster, ask about a rush order before you pay, not after.
Screen Printing vs Digital Printing: Which Is Right for Your Design?
Screen printing suits bold designs in a few colours across larger runs. Digital printing (including direct-to-film) suits detailed, multi-colour artwork and smaller quantities, where setup costs would otherwise make screen printing expensive.
| Method | Best For | Colour Limits | Setup Fees |
|---|---|---|---|
| Screen printing | Bulk runs, simple bold designs | One screen per colour | Yes, per colour |
| Digital printing | Detailed or photo designs | Unlimited colours | No |
| Direct-to-film | Small runs, complex artwork | Unlimited colours | No |
| Embroidery | Logos, polos, workwear | Limited thread colours | Yes, per design |
The rule of thumb: the more colours and the smaller the run, the more digital printing wins on cost. Fewer colours and higher volume favour screen printing.
T-Shirt Design Tips for Printing That Actually Work
Design for the print method, not just the screen. Thin lines under 1mm often fill in or disappear, and fine gradients can band on screen-printed garments. Keep text large enough to read from a metre away.
A few practical rules:
- Avoid hairline strokes and tiny serif fonts
- Leave a margin from seams and hems
- Test your design at actual print size, not zoomed in
- Keep critical elements away from the edges of the print area
Text customisation is where most people trip up. Spell-check names and dates twice. Once the screen is made, corrections mean a new setup fee.
Understanding Bulk Custom Shirt Pricing
Bulk custom shirt pricing depends on quantity, print method, number of colours and garment choice, so there's no single figure that applies to every order. What most guides skip is the actual arithmetic behind the per-unit price. Here's how to work it out yourself before you request a quote.
The four cost layers
Every custom shirt quote is built from four layers stacked on top of each other:
- Setup fees: a fixed charge per design, and for screen printing a fixed charge per colour. This is the layer that shrinks fastest per shirt as volume rises.
- Garment cost: the blank shirt itself, which drops at wholesale tiers as you cross quantity thresholds.
- Print cost: the per-impression charge for applying the design. Screen printing falls steeply per unit at scale; digital and direct-to-film stay relatively flat.
- Extras: rush turnaround, specialty inks, multiple print locations, individual folding and bagging, and split delivery to multiple addresses.
How setup fees dilute with volume
The clearest way to understand bulk pricing is to watch a fixed setup fee spread across a growing order. Suppose a one-colour screen print carries a setup charge of $40. That single charge is the same whether you print 10 shirts or 500:
- At 10 shirts, the setup adds $4.00 per shirt
- At 50 shirts, it adds $0.80 per shirt
- At 100 shirts, it adds $0.40 per shirt
- At 500 shirts, it adds $0.08 per shirt
Now add a second colour and the setup doubles to $80, which is why multi-colour screen printing only makes economic sense at higher volumes. Digital printing removes the setup fee entirely, which is why it wins on small runs even when its per-impression cost is higher.
A worked cost-per-unit example
Take a midweight cotton tee with a single-colour front print. The garment might sit at one wholesale tier for a small run and drop to a lower tier once you cross a quantity break. Stack the layers:
| Layer | Small run (e.g. 20 shirts) | Larger run (e.g. 100 shirts) |
|---|---|---|
| Setup fee (per design/colour) | Spread over few units, high per shirt | Spread over many units, low per shirt |
| Garment | Higher tier price | Lower wholesale tier |
| Similar per impression | Similar per impression | |
| Extras | Often waived or minimal | May add folding, bagging, split delivery |
The pattern to internalise: fixed costs (setup) fall per unit as volume rises, variable costs (garment, print) fall only when you cross a supplier's quantity break. That's why the biggest per-unit savings usually come from the first jump in volume, not the last.
Where the savings actually stop
Beyond a certain point, adding more shirts stops lowering the per-unit price meaningfully, because the setup fee is already diluted to near zero and you're left with variable costs. Ordering 500 shirts when you need 120 doesn't save money, it just ties up capital in stock you may never use. Work out your realistic quantity first, then ask for quotes at the next tier up to see whether the jump is worth it.
For current pricing on your specific order, check 123t Australia's site or request a quote with your quantity and design.
Choosing the Right Fabric and Garment Weight
Fabric weight, measured in grams per square metre (GSM), decides how a shirt feels and how well it prints. But weight alone doesn't tell you which fabric suits your job. The fibre blend matters just as much, because cotton, polyester and blends behave very differently under a print and against the skin. Here's how to match fabric to use case.
The weight bands and what they mean
| Fabric | Typical Weight | Best For |
|---|---|---|
| Lightweight cotton | 140-160 GSM | Summer, casual wear, warm climates |
| Midweight cotton | 170-190 GSM | Everyday tees, group orders, retail-style shirts |
| Heavyweight cotton | 200+ GSM | Bold prints, durability, workwear |
| Cotton-poly blend | 150-180 GSM | Soft feel, colour retention, sportswear |
Cotton vs polyester vs blends: performance by use case
Weight is only half the story. The fibre decides how the shirt wears, washes and holds a print.
100% cotton is the default for casual and retail-style shirts. It's breathable, takes screen-printed and digital inks well, and feels substantial. Its weaknesses are shrinkage on the first hot wash and slower drying. For bold solid-colour prints, cotton gives the cleanest result because the ink sits on a stable, matte surface.
100% polyester is the choice for sportswear and performance shirts. It wicks moisture, dries fast and holds colour well, but it's slicker, so some inks need a bonding agent to adhere. It also has a shinier finish that can make large prints look plasticky. For gym, running and team sport shirts, polyester's moisture management outweighs its feel.
Cotton-poly blends split the difference. A 50/50 or 60/40 blend shrinks less than pure cotton, resists wrinkling, and holds printed colour longer because the polyester component stabilises the fabric. The trade-off is a slightly less premium hand-feel than pure cotton. For large group orders where consistency across many washes matters, blends are often the pragmatic pick.
Tri-blends (cotton, polyester and rayon) are softer and drape better, making them popular for fashion-forward personal shirts. They're less durable under heavy print coverage, so keep designs lighter.
Matching fabric to print method
Fabric and print method interact. A few practical pairings:
- Screen printing on heavyweight cotton: the classic combination for bold, durable prints on bulk runs.
- Digital or direct-to-film on blends: detailed, multi-colour artwork on softer fabrics where setup fees would be prohibitive.
- Embroidery on polyester polos and workwear: the thread sits on top of the fabric, so a stable, slightly heavier knit holds the logo shape better than a thin tee.
- Water-based inks on cotton: the ink bonds into the fibre for a soft, vintage finish that polyester can't replicate as easily.
Shrinkage, colour retention and care
Two performance factors buyers rarely ask about until it's too late:
- Shrinkage: pure cotton can shrink noticeably on a first hot wash. Pre-shrunk or blended garments reduce this risk. If sizing accuracy matters for a group order, ask whether the blank is pre-shrunk.
- Colour retention: dark cotton fades over time, especially with repeated washing and sun exposure. Blends and polyester hold dark colours longer, which matters for uniforms and workwear that get washed weekly.
If you're unsure, order one sample in each candidate fabric and wash it before committing to a full run. A single sample costs far less than reprinting a whole order in the wrong cloth.
Common Design Mistakes and How to Avoid Them
The most common mistake is uploading a low-resolution image, usually a logo pulled from a website or social media. It looks fine on screen and prints blurry. Always supply a vector file or a 300 DPI raster at final print size.
Other frequent errors:
- Wrong colour mode: design in RGB and the printed colours shift. Supply CMYK or Pantone references.
- Text too close to seams: it gets cut off or distorted during printing.
- Ignoring the mockup: small placement errors become obvious once printed.
- No bleed allowance: designs that touch the print edge can show white borders.
Turnaround Times, Shipping, and Rush Orders
Standard turnaround covers production plus shipping, and it varies with order size and print method. Larger screen-printed runs take longer than small digital orders because each colour needs its own screen and pass.
Plan around three phases: artwork approval, production, and delivery. Artwork approval is the one you control, so approve your mockup promptly. If you're ordering for a fixed date like a birthday or Christmas, build in a buffer and ask about rush options early.
Shipping logistics matter for bulk orders going to multiple addresses. Confirm whether you need split delivery before checkout, as it affects both cost and timing.
Sustainability and Eco-Friendly Inks
Water-based and plastisol-free inks reduce the chemical load in textile printing, and they're increasingly common for custom apparel. Water-based inks sit in the fabric rather than on top of it, giving a softer finish that many people prefer.
For buyers who care about environmental impact, ask what inks and processes a printer uses. Recycled and organic cotton garments are also available, though they usually cost more.
Conclusion
Ordering custom shirts comes down to preparation: clean artwork, the right print method, and a realistic deadline. Get those three right and the rest is straightforward.
At 123t Australia, we make it easy with in-house created designs, personalised custom clothing, and high-quality materials. Our 60-day return policy and free shipping give you room to order with confidence.
Get started with 123t Australia and turn your design into shirts people actually want to wear.
Frequently Asked Questions
How much does it cost to get a custom made shirt?
Pricing depends on quantity, garment style, print method, and delivery timeline. Bulk custom shirt pricing drops significantly per unit as you order more. Setup fees may apply for screen printing, while digital printing often has no minimums. For current pricing on custom shirts, check 123t Australia's website or request a quote with your design and quantity.
What file format is best for custom shirt printing?
Vector files like AI, EPS, or PDF are best because they scale without losing quality. If you only have a PNG or JPG, aim for at least 300 DPI at the final print size. Low-resolution files lead to blurry or pixelated prints. Most custom shirt providers accept common file types and will let you know if your artwork needs adjustment before printing.
What is the difference between screen printing and digital printing?
Screen printing uses stencils and ink pushed through a mesh screen, which keeps costs low for large orders of one design. Digital printing, including direct-to-film, prints the design directly onto the garment, making it better for detailed artwork, photos, and small runs with no minimums. For bulk orders with simple designs, screen printing usually wins on price. For complex or one-off designs, digital printing is more practical.
How do I choose the right fabric for custom shirts?
Fabric weight is measured in grams per square metre (GSM). Lightweight options around 150 GSM suit warm weather, while 180-220 GSM gives a more substantial feel that holds shape and print well. Cotton is breathable and takes ink nicely; cotton-poly blends resist shrinking and wrinkles. If the shirt will be worn often or washed frequently, a mid-weight cotton or blend offers the best balance of comfort and durability.
