Ink Coverage &
Print Cost Calculator
Estimate your printing cost per shirt based on ink coverage, print area, method, and order size. Compare screen print, DTF, DTG, and sublimation costs.
Print Cost Per Shirt
Cost at different quantities
| Qty | Per Shirt | Total |
|---|---|---|
| 25 | $4.81 | $120.36 |
| 50 | $3.31 | $165.72 |
| 100 | $2.56 | $256.44 |
| 250 | $2.11 | $528.60 |
| 500 | $1.96 | $982.20 |
| 1000 | $1.89 | $1889.40 |
How to Estimate Ink Cost Per T-Shirt
Ink cost is one of the most overlooked expenses in apparel decoration. Many new brands focus on the blank garment cost but forget that ink, film, and setup fees can add $1–5+ per shirt depending on the design complexity and print method.
Ink Coverage Explained
Coverage percentage refers to how much of the print area is covered by ink. A small text logo might be 5–10% coverage, while a full-color photograph is 80–100%. Higher coverage = more ink = higher cost.
For screen printing, each color requires a separate screen ($25–50 setup each). A 3-color design costs 3× the ink of a 1-color design, plus 3× the setup fee. This is why screen print gets cheaper at volume — the setup fee is spread across more shirts.
DTF and DTG are full-color processes with no per-color cost, but the ink itself is more expensive per square inch. They're better for complex, multi-color designs at lower quantities.
Cost Comparison by Method
Screen Print — Cheapest at 50+ units for simple designs (1–3 colors). Setup costs make it expensive for small runs. Ink cost: ~$0.01–0.02/sq inch.
DTF Transfer — No setup, full color. Best for 1–50 units or complex designs. Ink + film cost: ~$0.02–0.03/sq inch.
DTG — Highest ink cost but zero setup and infinite colors. Best for on-demand, one-offs. Ink cost: ~$0.03–0.05/sq inch.
Sublimation — Cheapest ink cost but only works on white/light polyester. Ink cost: ~$0.008–0.015/sq inch.
Now see how your design looks on a real 3D garment.
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