Custom apparel has become a major trend across the country, with businesses, sports clubs, events, creative brands and families all searching for premium yet affordable custom shirts in Australia. But with so many printing methods, fabric types, garment brands and decoration options available, figuring out the final price can feel overwhelming.

This in-depth guide breaks down the true cost factors behind custom printing so you can make smarter, budget-friendly decisions whether you're ordering 1 shirt or 1,000. If you're working with local suppliers offering custom t shirt printing in Sydney, Melbourne, Brisbane or other cities, understanding these elements will help you compare quotes with confidence.

Why Price Can Vary So Much for Custom Shirts?

Not all custom shirts are created equal. The cost depends on the garment, the printing technology, the complexity of your artwork, and even where the shirt is being printed. Customers often believe custom printing is expensive but with the right choices, you can achieve high-quality results at a much lower cost.

Let’s break down the key pricing factors step by step.

1. The Garment Brand and Fabric Type

One of the biggest influences on the cost of custom shirts Australia is the garment itself.

1.1 Popular Shirt Brands

Pricing can vary significantly between brands such as:

• AS Colour – premium quality, higher cost
  
  

• Gildan – affordable, widely used for bulk
  
  

• Syzmik – ideal for durable workwear
  
  

• American Apparel – fashion-focused, higher price
  
  

• JB’s Wear – budget-friendly and reliable
  
  

Premium brands naturally raise the price, but they offer better comfort, longevity and print results.

1.2 Fabric Choices and Their Costs

Different fabrics offer different benefits, and each affects pricing:

Cotton (Most Popular & Affordable)

• Soft, breathable
  
  

• Perfect for DTG and screen printing
  
  

• Great cost-to-quality ratio
  
  

Cotton/Poly Blends

• Better durability and shape retention
  
  

• Slightly more expensive than basic cotton
  
  

Polyester & Performance Fabrics

• Premium for sportswear and uniforms
  
  

• Ideal for moisture-wicking and activewear
  
  

• Generally more expensive
  
  

Organic & Sustainable Fabrics

• Eco-friendly but higher-priced
  
  

• Popular for fashion brands and conscious consumers
  
  

Fabric makes up 40–60% of the final shirt cost.

2. Printing Method: The Biggest Cost Factor

Printing techniques dramatically affect the price. Each method has different strengths and price points, especially when using custom t shirt printing in Sydney where high-quality print technology is widely available.

2.1 Direct-to-Garment (DTG)

Best for detailed designs and small orders.

Pricing impact:

• More cost-effective for 1–20 shirts
  
  

• Higher cost per print than screen printing for bulk
  
  

• No setup fees
  
  

Ideal for artwork with gradients, photos and multiple colours.

2.2 Direct-to-Film (DTF) Transfers

Now the most popular option in Australia thanks to its durability and versatility.

Pricing impact:

• Affordable for small and medium orders
  
  

• Works on all fabrics
  
  

• Slightly cheaper than DTG but more flexible
  
  

Perfect for logos, multi-colour artwork and fast turnaround jobs.

2.3 Screen Printing

The best option for large bulk orders.

Pricing impact:

• Low cost per shirt when ordering 50+
  
  

• High setup fees due to screens
  
  

• Price increases with every additional colour
  
  

For big promotional events or brand merchandise, screen printing offers unbeatable value.

2.4 Embroidery

A premium choice for business polos and workwear.

Pricing impact:

• Higher base cost
  
  

• Price depends on stitch count
  
  

• Long-lasting and professional finish
  
  

Embroidery adds perceived value but increases total cost.

2.5 Vinyl Names & Numbers

Common for sports uniforms.

Pricing impact:

• Charged per name/number
  
  

• Great for personalisation
  
  

• Not ideal for large graphics

3. Artwork Complexity and Print Size

Your design can increase or decrease the price depending on several factors:

✔ Number of colours

Screen printing becomes more expensive with every extra colour.

✔ Print placement

Multiple print locations = higher cost:

• Front
  
  

• Back
  
  

• Sleeve
  
  

• Inside label
  
  

✔ Size of print

A full-chest or full-back design uses more ink than a small logo.

✔ Artwork preparation

If the supplier must clean, redraw or vectorise your artwork, you may incur extra fees.

Simple, clean artwork helps keep costs low.

4. Quantity: Bulk Orders Save Money

The quantity of shirts ordered is one of the biggest pricing influences:

• 1–10 shirts: DTG or DTF recommended; higher cost per shirt
  
  

• 20–50 shirts: Balanced cost; most printing methods suitable
  
  

• 50–500 shirts: Screen printing becomes significantly cheaper
  
  

• 500+ shirts: Wholesale pricing available
  
  

Bulk buying can reduce the price by 30–60%, making it ideal for events, promotions and uniforms.

5. Turnaround Time & Urgency Fees

Need your shirts quickly?
Printers offering custom t shirt printing in Sydney often have express options, but urgency may add fees such as:

• Rush turnaround
  
  

• Priority production
  
  

• Same-day or next-day printing
  
  

Planning ahead is one of the best ways to reduce cost.

6. Extra Features and Add-Ons

Optional features can increase the final price:

✔ Neck label printing or tag removal

Ideal for clothing brands.

✔ Specialty inks

Glow-in-the-dark, metallic, puff, or neon inks.

✔ Packaging

Individual bagging, folding or tagging.

✔ Garment upgrades

UPF shirts, heavy-duty workwear, eco-fabrics, oversized fits.

These add-ons are optional but great for premium branding.

7. Location: Local vs Overseas Printing Costs

Choosing a local provider for custom shirts Australia offers major benefits:

• Faster shipping
  
  

• Consistent colour accuracy
  
  

• Clear communication
  
  

• Easier reorders
  
  

• No international delays
  
  

Sydney, in particular, is known for high-standard printing technology. Custom t shirt printing in Sydney generally offers competitive pricing with superior service, especially for urgent orders or complex designs.

How to Keep the Cost Low Without Sacrificing Quality

Here are practical tips to save money:

✔ Order in bulk

Bigger quantities equal lower cost per shirt.

✔ Use fewer colours

Especially for screen printing.

✔ Choose standard fabrics (cotton or blends)

Avoid premium unless necessary.

✔ Keep artwork simple

Reduces setup time and preparation fees.

✔ Choose one print location

Minimises ink and labour costs.

✔ Plan ahead

Avoid rush fees by giving suppliers enough time.

Conclusion

When it comes to custom shirts Australia, the final price depends on multiple factors including fabric, shirt brand, printing method, artwork complexity, quantity and turnaround time. By understanding these elements, you can make smarter choices that deliver high-quality results while staying within budget.

Local printers offering custom t shirt printing in Sydney also give you the advantage of fast service, consistent colour quality and affordable options for both small and large orders. Whether you're printing shirts for your business, clothing brand, sports club or event, knowing what influences the final price ensures you get the best value every time.