DTG Printing Costs:

DTG printing costs depend on ink use, shirt color, and printer type. On average, it’s $2–$5 per shirt, including ink and pretreatment. Calculating ROI helps you see profit margins, compare equipment prices, and plan your pricing strategy.

DTG printing offers low setup costs and high-quality results, ideal for small batches or custom apparel.

Why DTG Printing Costs Matter

DTG (Direct-to-Garment) printing is loved for its bright, detailed prints and zero setup hassle. But before jumping in, you’ve got to know one thing, what’s the real cost per shirt?

When you know your cost per shirt, you can price smarter, protect profits, and decide if DTG printing fits your business goals.

DTG uses inkjet tech to print directly onto fabric, making it great for small runs and custom orders. The challenge is understanding where your money goes, ink, pretreatment, blanks, and maintenance all add up fast.

This guide is for small brands, resellers, and print shops who want to:

• Break down true DTG printing costs
• Use a simple ROI formula to plan profit
• Compare DTG with screen or DTF printing

How to Use This DTG Cost Per Shirt Calculator

This tool makes it super easy to figure out your real printing costs before you hit “print.” Here’s how to use it like a pro:

1. Enter your fixed costs.
Add things like your printer, heat press, software, or setup costs. These are your one-time or long-term investments that get divided across every shirt you print.

2. Fill in your variable costs.
Enter what each shirt actually costs you, blank garment price, ink, pretreatment, labor, and electricity. These numbers change depending on design and fabric.

3. Choose how many shirts you’re printing.
The more you print, the lower your per-shirt cost will be. The calculator automatically adjusts your total cost and profit based on your quantity.

4. Add your selling price.
Enter what you plan to charge your customers per shirt. The calculator will instantly show your profit per shirt, ROI percentage, and even break-even point.

5. Compare and experiment.
Try changing the numbers, lighter shirts, bulk runs, or simpler designs, to see how each factor affects your profit. It’s an easy way to spot what’s worth printing and what’s not.

All Cost Components

Knowing every cost, from printer upkeep to the last drop of ink, helps you price shirts accurately and protect your margins. Small cost differences, multiplied across hundreds of shirts, can decide whether you profit or just break even.

Fixed / Startup Costs

These are the one-time investments that get your DTG setup running.

• Printer purchase cost: Entry-level DTG printers start around $3,000–$6,000, while professional models can exceed $15,000. Cheaper units work for small batches, but high-volume shops usually need faster print speeds and larger platen sizes.
• Pretreatment equipment, heat press, and software: You’ll need a heat press for curing and a pretreatment sprayer (manual or automatic). Don’t forget design software or RIP tools for color control.
• Depreciation and maintenance: Like any machine, your printer loses value and needs care. Expect routine cleaning, printhead flushes, and part replacements, which can cost a few hundred dollars annually.

Variable / Per-Shirt Costs

These expenses hit with every order and directly affect your profit margin.

• Blank garment cost: A basic cotton tee runs $1.50–$4, depending on brand, fiber blend, and size. Ringspun cotton gives smoother results than rougher fabrics.
• Ink cost: On light shirts, ink may cost $0.50–$1.00, but dark garments (which need a white underbase) can reach $2–$3 per print.
• Pretreatment cost: For dark shirts, pretreatment adds another $0.25–$0.50 per shirt.
• Labor and overhead: Each print takes 3–6 minutes including setup, pressing, and cleanup. Add small amounts for electricity, water, and labor time per shirt.

Other Hidden or Overlooked Costs

These costs can sneak into your bottom line if you’re not tracking them.

• Waste and reprints: Test prints, misalignments, or defective blanks add up over time.
• Design complexity: Larger, full-color artwork consumes more ink and print time.
• Shipping and packaging: Mailing supplies and postage can add $1–$3 per order.
• Local overhead: Rent, utilities, and insurance vary by region but should be factored into total operating cost.

How to Calculate Cost per Shirt – Step-by-Step

Once you know your expenses, it’s time to figure out what each printed shirt actually costs you. This helps you set the right selling price and measure your ROI accurately.

DTG profitability starts with precision. When you break your costs down shirt by shirt, you’ll know exactly where to adjust, If that’s optimizing designs, ordering blanks smarter, or tweaking prices to boost ROI.

Step 1: Use a Simple Formula

Start with this quick calculation:

Total Cost per Shirt = (Fixed Cost ÷ Number of Shirts) + Variable Cost per Shirt

• Fixed cost includes printer, software, heat press, and setup expenses.
• Variable cost covers blanks, ink, pretreatment, labor, and electricity.

Step 2: Compare White vs Dark Shirt Costs

Dark shirts always cost more because they need white underbase ink and pretreatment. Here’s a quick example:

Item	White T-Shirt	Dark T-Shirt
Blank shirt	$2.00	$2.50
Ink cost	$0.80	$2.40
Pretreatment	—	$0.40
Labor & overhead	$0.75	$0.75
Fixed cost share	$1.00	$1.00
Total Cost per Shirt	$4.55	$7.05

So, if you sell the white shirt for $15 and the dark one for $20, your gross profit is roughly $10.45 and $12.95 per shirt, respectively.

Step 3: See How Quantity Changes Cost

Printing in bulk spreads your fixed costs across more shirts, dropping your per-shirt price significantly.

Quantity	Fixed Cost Allocation	Total Cost (White)	Total Cost (Dark)
50 shirts	$1.00	$4.55	$7.05
200 shirts	$0.25	$3.80	$6.30
500 shirts	$0.10	$3.65	$6.15

As you can see, the more you print, the cheaper each shirt gets. Bulk orders are where DTG starts to show real profitability, as noted by .

Step 4: Use a Simple Calculator or Worksheet

To make this easy, use a DTG cost calculator or spreadsheet that lets you plug in your own numbers, printer price, ink use, blank cost, and print time.

Setting Your Sale Price & Calculating ROI

Pricing your DTG shirts isn’t just about covering costs, it’s about understanding your market and making data-backed decisions. Once you know your ROI and break-even point, you can scale confidently, adjust margins smartly, and grow your business sustainably.

Determining the Selling Price

Your selling price should balance cost, competition, and customer value. Here’s a simple way to think about it:

Selling Price = Total Cost per Shirt + Desired Profit Margin

Most DTG printers aim for a 40–70% profit margin depending on design complexity and target market.

To stay competitive:

• Check local and online pricing. Most shops charge $15–$25 per shirt, depending on print size and fabric quality.
• For example, a basic DTG tees around $20 for single orders, showing that customers are willing to pay more for convenience and custom prints.

Tip:
If your audience values unique, on-demand designs, you can price higher. If you’re chasing volume, competitive pricing matters more.

ROI Formula and Break-Even Point

Your ROI tells you how profitable your prints are.

ROI Formula:
[
ROI = \frac{(Sale\ Price – Total\ Cost)}{Total\ Cost} \times 100
]

Example:
If your cost is $5 and you sell the shirt for $20, then:
[
ROI = \frac{(20 – 5)}{5} \times 100 = 300%
]

That means you’re earning three times what you spend per shirt.

To find your break-even point, divide your fixed costs by your profit per shirt.

Example:
If your equipment and setup cost $3,000 and your profit per shirt is $10, you’ll need to sell 300 shirts to break even. After that, every sale is pure profit.

Volume & Order Size Impact

Your pricing strategy changes with scale. Small runs inflate your cost per shirt because you’re spreading fixed costs across fewer items.

Order Size	Approx. Fixed Cost per Shirt	Example Total Cost	Suggested Sale Price
25 shirts	$1.50	$6.50	$18–$22
100 shirts	$0.50	$5.50	$15–$18
500 shirts	$0.15	$4.75	$13–$16

Larger batches drop your per-shirt cost and boost your ROI, but don’t overlook the profit in niche or custom orders. Personalized or limited-edition prints often justify premium pricing, since customers value exclusivity over quantity.

Key Factors That Drive Cost Variations

Not all DTG prints cost the same, even if they look similar. Here’s what really makes the price swing.

• Garment color & fabric type
  White cotton shirts print faster and use less ink. Dark or blended fabrics need a white underbase, pretreatment, and more passes, raising ink use and time.
• Design size & placement
  Bigger or multi-location prints = more ink + more print time. A front chest logo might cost half as much as a full-front and back design.
• Order quantity
  Small runs carry higher costs since setup and prep time don’t scale. Bulk orders spread those fixed costs, so your per-shirt cost drops.
• Local labor & utility costs
  Shops in high-cost areas pay more for wages, electricity, and water, which all affect final pricing.
• Machine efficiency & maintenance
  Well-maintained printers with consistent output waste less ink and reduce reprints. An older or poorly calibrated machine can quietly eat into profit.
• Market positioning
  Premium brands can charge more for the same print because of perceived quality and packaging. Budget-focused sellers must keep tighter margins.

💡Tip: Always track your true per-shirt cost per job type. You’ll spot where small changes, like optimizing design placement or batch size, can boost your ROI without raising prices.

DTG vs Other Printing Methods: Cost Comparison

DTG shines in customization, color accuracy, and low-volume flexibility. Screen and DTF win on high-volume or specialty materials. The real profit lies in knowing which jobs fit DTG best.

Knowing how DTG stacks up against other print methods helps you decide when it’s actually the smarter (and cheaper) choice.

• DTG vs Screen Printing
  Screen printing wins for bulk orders. Once you’ve paid for setup (screens, films, and color separations), each additional shirt costs pennies. But for small runs or full-color artwork, setup fees kill profit.
  • Setup cost: High (per color)
  • Per-shirt cost: Low for 50+ shirts
  • Best for: Simple designs, large batches
  • DTG wins when: You’re printing small runs or custom one-offs with detailed or multi-color graphics.
• DTG vs DTF / Heat Transfers
  DTF (Direct-to-Film) is catching up fast. It’s better for dark or mixed fabrics and has a softer hand feel than old-school vinyl. But it adds a film layer, so it doesn’t breathe like DTG ink.
  • Setup cost: Moderate
  • Durability: DTF often outlasts DTG
  • DTG wins when: You want a smooth, “printed-in-fabric” look on cotton garments or need one-offs without film waste.
  • DTF wins when: You’re printing on polyester, dark blends, or want to preprint and store transfers for later.
• When DTG Makes Sense vs Outsourcing
  If you’re testing new designs, doing print-on-demand, or fulfilling micro-orders (under 25 shirts), DTG gives you flexibility and no minimums.
  But if your average order is 100+ units, outsourcing or screen printing might cut costs per unit in half.

If you’re still exploring your options, check out our full DTG Printer Comparison guide to see how different models stack up in terms of cost, maintenance, and print quality.

Effective Strategies in Maximizing ROI with DTG Printing

Profit in DTG isn’t about cutting corners, it’s about tightening the process. Each small efficiency, from smarter batching to design tweaks, moves your ROI needle up.

1. Batch your prints efficiently
Group similar orders together to cut setup and pretreatment time. Running shirts back-to-back saves ink, energy, and labor hours, all small wins that stack up fast.

2. Use the right garments
Pick high-quality cotton or blends that absorb ink evenly. Cheap shirts might look like a deal upfront but often need reprints or waste ink, which eats into your profit.

3. Simplify your designs
Large, full-color prints use way more white ink, especially on dark shirts. Simplifying your artwork or reducing print area can drop your ink cost by 20–30%.

4. Maintain your printer regularly
A clean, calibrated printer runs smoother and wastes less ink. Schedule short maintenance sessions instead of waiting for clogs or breakdowns that stop production cold.

5. Price for value, not just cost
Don’t compete on being the cheapest. Add personalization, premium packaging, or faster turnaround to justify higher prices. Customers pay more for convenience and quality.

6. Reuse your data
Track your true cost per job and profit margins using a simple sheet or calculator. Over time, you’ll see which designs, fabrics, and customer types bring the best ROI.

7. Build repeat business
Offer loyalty discounts, bundle deals, or monthly merch subscriptions for steady orders. The more consistent your volume, the faster you recover your fixed costs.

Real-World Example: 500 Dark Shirts ROI Breakdown

Case: A small streetwear brand printed 500 dark cotton shirts with custom artwork using DTG.

Item	Cost per Shirt	Total Cost
Blank shirt (premium cotton)	$4.50	$2,250
Pretreatment + ink	$3.00	$1,500
Labor + overhead	$1.50	$750
Total Cost	$9.00	$4,500

They sold each shirt for $22, grossing $11,000 in total.

Profit: $11,000 − $4,500 = $6,500
ROI: [(22 − 9) ÷ 9] × 100% = 144%

What went well:

• Bulk order reduced ink and labor costs per shirt.
• Consistent artwork meant faster print runs and less waste.

What they learned:

• Pretreatment costs can spike if humidity or fabric type changes.
• Packaging and labeling added about $0.75 per shirt,often overlooked.

From a wholesale view (Subli Genius Print insight):
When you move into bulk DTG orders, efficiency and prep matter more than speed. Proper batching, consistent blanks, and predictable artwork make all the difference. Bulk buyers save when designs are optimized upfront, keeping your margins healthy even with competitive pricing.

Which is More Cost-Effective: DTG or Traditional Printing Techniques?

If you run a small shop or print on demand, DTG gives better ROI with minimal setup and flexible designs. If you’re printing hundreds of the same shirt, screen printing wins on cost per unit.

DTG (Direct-to-Garment) is great for short runs, custom prints, or full-color artwork. There’s no screen setup, so you can print one shirt or a hundred with no big prep cost. However, the ink and print time per shirt are higher, which makes DTG less ideal for bulk orders.

Screen printing, on the other hand, shines for large batches. Once the screens are made, the cost per shirt drops fast. But if you’re only printing a few designs or constantly changing artwork, setup fees and time eat into profits.

Here’s a quick side-by-side snapshot:

Factor	DTG Printing	Screen Printing
Best for	Small batches, full-color designs	Large batches, simple designs
Setup cost	None	High (screens, prep)
Cost per shirt (small run)	Higher	Lower only in bulk
Color flexibility	Unlimited	Limited per screen
Turnaround time	Fast	Slower for setup
Profit margin	Higher for custom jobs	Higher for volume orders

DTG Printer Under $1000

A DTG printer under $1000 sounds tempting, but in most cases, it’s a short-term learning investment, not a long-term business asset. For serious profit and scalability, your ROI improves when you invest in quality equipment, reliable inks, and consistent output.

• Some mini A4-size printers are listed around $900–$1,000 from lesser-known manufacturers.
• Most “true” DTG machines (with full white ink + dark garment capability) start at $10,000+.
• One budget guide warns that “most true DTG printers under $1,000 are refurbished, modified, or DIY kits.”

The Reality Check

Most true DTG printers, with proper white ink support, durable print heads, and wide platens, start around $10,000 and up. Anything below $1,000 is typically a DIY conversion, refurbished unit, or experimental machine.

While these can help you learn the ropes, they’re not built for business-level reliability. Frequent maintenance, inconsistent colors, and downtime can drive up your real cost per shirt, cutting into your ROI fast.

What you get and what you give up

Pros

• Lower entry cost, less financial risk if you’re just testing out.
• Great for light-colored garments (if machine lacks white ink support).

Cons

• Likely smaller print area (A4 size), slower speed, fewer quality/performance features.
• May lack robust white ink or automated pretreatment systems, big disadvantage if you’ll print dark shirts.
• Support, parts, reliability may be weaker, testimonials suggest budget machines “work decent for a few weeks” then cause trouble.

For new print business owners, the Top 5 DTG Printers for Newbies post highlights affordable and beginner-friendly options to help you start smart.

Budget DTG Printer Options

1. Neixo A4 DTG Printer (Model: NX4320)

• Price: ~ $950 for a desktop A4 machine.
• Pros: Very low entry-cost, supports white ink for dark shirts, auto-clean system.
• Cons: Print area is small (A4 size ~210×320 mm) so not ideal for adult full-front large designs; after-sale/support may be weaker.
• Viable? If you’re experimenting, doing small prints, samples or kid shirts, yes. For full wholesale custom runs for adult apparel, you’ll likely hit limits.

2. Generic / Import A3/A4 DTG Machines Under $1,000

• Some Chinese manufacturers list “DTG printer under $1,000” models on sites like Alibaba.
• Pros: Very low upfront cost, possible to start with minimal investment.
• Cons: Unknown brand reliability, support/parts may be problematic; variable quality; might lack robust white ink/pretreatment features; might result in higher variable cost per shirt (wasting ink, more reprints).
• Viable? Risky for a serious business. Good for hobby or side-project but I’d be cautious for wholesale/custom job volume.

3. Reality Check: Established DTG Machines Start Much Higher

• Guides show true high-volume machines often cost $10,000+.
• What that means: Sub-$1,000 machines are trade-offs.
• Viable? Only if you accept smaller size, slower speeds, more manual maintenance.

Looking to understand how DTG stacks up against other print types? Dive into our Comparing DTG, DTF, Sublimation, and Embroidery article for a full cost and quality breakdown.

Budget DTG vs Professional DTG

If you’re just dipping your toes into DTG or offering occasional custom jobs, a budget machine might work as a learning tool. But if you’re running a business like Subli Genius Print with regular orders, dark garments, and quality expectations, professional gear gives you a more reliable path to profit.

Feature	Budget DTG Printer	Professional DTG Printer
Typical Price Range	~$1,000 – $3,000 (or used/refurbished)	~$15,000 – $30,000+ for true production models
Print Area & Speed	Smaller platen, slower throughput (good for low volume)	Larger platen, high speed & volume output
Dark Garment Capability	Often limited white ink/support, higher cost per dark shirt	Full white ink systems, optimized for dark garments, lower cost per unit
Maintenance & Reliability	Higher risk of downtime, fewer support options	Built for continuous production, better support & durability
Best For	Hobby, one-off jobs, testing DTG process	Custom apparel brands, wholesale, high volume production
Cost Per Shirt Impact	Higher variable cost per shirt, slower ROI	Lower cost per shirt at scale, faster ROI when volume is high