Best Apparel Printing Method for Small Orders — What to Use When You Need Just a Few Shirts

Best Apparel Printing Method for Small Orders

Small orders — fewer than 24 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 12 pieces, DTF (Direct-to-Film) printing is almost always 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 to recover the setup cost of making screens. On a 4-shirt run, screen printing is economically impractical. DTF is not.

What About 12–24 Pieces?

In the 12–24 piece range, the right choice depends on design complexity:

  • Simple design with 1–2 colors, 24 pieces: Screen printing is likely more cost-effective
  • Full-color or complex design, any quantity under 24: DTF is the better choice
  • 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 in the 12–24 range 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 1–11 pieces: DTF printing. It’s the only print method that is economically practical at very small quantities without compromising quality.

For 12–23 pieces with a simple design: the answer varies — DTF may still win, or screen printing may be cost-competitive. Get quotes on both.

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
2–11 pieces DTF No minimums, no setup cost
12–23 pieces, simple design DTF or Screen Printing Get quotes on both
12–23 pieces, full-color design DTF Color count doesn't increase DTF cost
24–47 pieces, 1–4 colors Screen Printing Setup cost now efficient
48+ pieces, standard design Screen Printing Most cost-effective at this quantity
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.