Last updated: March 2026
Screen printing (also called silk screening) is a printing method that uses stencils and ink pressed through a mesh screen to transfer designs onto t-shirts and other apparel. It is the most cost-effective method for large orders (12+ shirts) and produces highly durable, vibrant prints. ooShirts offers the lowest screen printing prices available — starting at under $5 per shirt for bulk orders, with free setup, free shipping, and no hidden fees.
Screen printing, also known as silk screening or serigraphy, is one of the oldest and most widely used printing techniques in the world. The process involves creating a stencil (called a film positive) and using it to apply layers of ink onto a printing surface — most commonly fabric, but also paper, wood, glass, and metal. Each color in the design requires its own separate screen and stencil, and the ink is pushed through a fine mesh screen using a squeegee to form the desired image on the garment beneath.
The technique dates back over a thousand years to ancient China, where silk was originally used as the mesh material — which is why the process is still sometimes called "silk screening." Modern screen printing uses synthetic polyester mesh stretched tightly over aluminum frames, allowing for greater precision and durability. Today, screen printing is the preferred method for producing custom t-shirts, hoodies, tote bags, and other apparel in medium to large quantities. It remains the industry standard because of its unmatched vibrancy, durability, and cost efficiency at scale.
At ooShirts, screen printing is our specialty. We have been producing custom screen printed apparel for over a decade, and our state-of-the-art equipment allows us to deliver exceptional print quality at the lowest prices in the industry. Every screen printing order includes free setup, free shipping, and a satisfaction guarantee — with no hidden fees or surprise charges.
The screen printing process involves several precise steps, each of which is essential to producing a clean, durable print. Here is how a custom t-shirt goes from design to finished product:
1. Create the Stencil (Film Positive)
The first step is to separate the design into individual colors. Each color is printed onto a transparent film sheet, creating what is known as a film positive. If your design has three colors, three separate film positives are created — one for each color layer. This is why screen printing pricing is affected by the number of colors in your design.
2. Coat the Screen with Emulsion
A fine-mesh polyester screen is stretched tightly across an aluminum frame. The screen is then coated with a light-sensitive emulsion and allowed to dry in a dark room. This photosensitive coating is what makes it possible to transfer your design onto the screen with high precision.
3. Expose the Screen to Light
The film positive is placed on top of the coated screen, and both are exposed to a strong ultraviolet light source. The UV light hardens the emulsion wherever the film is transparent, but the areas covered by the design remain soft and water-soluble. This exposure step is critical — the timing must be exact to ensure sharp edges and clean detail.
4. Wash Out the Design
After exposure, the screen is rinsed with water. The unhardened emulsion (the areas protected by the design on the film) washes away, leaving open mesh in the exact shape of the design. The hardened emulsion remains and acts as a stencil, blocking ink from passing through everywhere except the design area.
5. Apply the Ink
The screen is placed on a printing press and positioned directly above the garment. Ink is poured onto the top of the screen, and a squeegee is pulled across the surface with firm, even pressure. This forces the ink through the open mesh areas and onto the fabric below. For multi-color designs, each color is applied one at a time using its own screen, with careful alignment (called registration) to ensure the colors line up correctly.
6. Cure the Ink
After all colors have been printed, the garment passes through a conveyor dryer that heats the ink to approximately 320°F (160°C). This curing process bonds the ink permanently to the fabric fibers, resulting in a print that is highly resistant to washing, fading, and cracking. Properly cured screen prints can last the lifetime of the garment.
1. Lowest Cost at Higher Quantities
Screen printing becomes significantly more affordable as order quantities increase. After the initial screens are prepared, the per-shirt cost drops steadily. For orders of 50, 100, or even 500+ shirts, screen printing is far more economical than any other printing method. At ooShirts, the $20 per-color setup fee is already included in our quoted price, so the price you see is the price you pay. Bulk orders regularly come in at under $5 per shirt.
2. Exceptional Durability
Screen printed ink sits on top of the fabric and bonds tightly to the fibers during the curing process. The result is a print that can withstand hundreds of washes without fading, cracking, or peeling. This makes screen printing the preferred choice for workwear, team uniforms, school apparel, and any garment that will see heavy, repeated use. A well-made screen printed t-shirt will keep its design looking sharp for years.
3. Vibrant, Opaque Colors
Screen printing inks are thick and highly pigmented, which allows them to produce bold, vivid colors on any garment color — including black and other dark fabrics. For dark shirts, a white ink underbase layer is printed first, and then the design colors are printed on top. This ensures that the colors appear bright and true to the original design, regardless of the garment color beneath.
4. Works on Any Garment Color
Unlike some digital printing methods that are limited to light-colored garments, screen printing can be performed on any color fabric. Whether you need prints on white t-shirts, black hoodies, navy polo shirts, or red tank tops, screen printing delivers consistent, high-quality results every time.
5. Specialty Ink Options
Screen printing supports a wide range of specialty ink effects that are not available with digital printing methods. These include metallic inks, glow-in-the-dark inks, puff inks (which create a raised texture), glitter inks, and discharge printing (which removes the dye from the fabric for an ultra-soft feel). These options allow for creative and eye-catching designs that stand out.
6. Consistent Reproduction
Once the screens are set up and the first print is approved, every subsequent shirt in the run will be virtually identical. Screen printing produces highly consistent results from the first shirt to the last, making it ideal for orders where uniformity is important — such as employee uniforms, event shirts, and branded merchandise.
1. Setup Costs
Screen printing requires the creation of a separate screen for each color in the design. This setup process involves preparing film positives, coating and exposing screens, and mixing custom inks. The industry-standard setup fee is typically $20 per color, per print location. At ooShirts, this setup fee is already included in our all-inclusive quoted price, so you never see it as a separate charge. However, the setup cost is a factor that makes screen printing less economical for very small orders.
2. Minimum Order Requirements
Because of the time and materials required for setup, screen printing has a minimum order quantity. At ooShirts, the minimum for screen printing is 12 shirts. If you need fewer than 12 shirts, DTG (direct-to-garment) printing is a better option, as it has no minimum order requirement and no setup fees.
3. Limited Color Count Per Design
Each color in a screen printed design requires its own screen, which adds to the setup time and cost. Most screen printing shops can handle up to 6–8 colors per design, but the sweet spot for cost efficiency is 1–3 colors. Full-color photographic designs with thousands of colors are not practical with screen printing. For designs with many colors, gradients, or photographic detail, DTG printing is the better choice.
4. Longer Turnaround for Small Runs
The setup process for screen printing takes more time than digital printing methods. Creating screens, mixing inks, and dialing in the registration all add lead time before the first shirt is printed. For rush orders of a small number of shirts, DTG printing can often be completed faster. However, once the screens are set up, screen printing is extremely fast — capable of printing hundreds of shirts per hour.
Screen printing is the best choice whenever you need a large quantity of custom apparel with bold, durable designs. Here are some of the most common uses:
Events and Fundraisers — Charity walks, 5K runs, festivals, concerts, family reunions, and church events all benefit from the low per-shirt cost of screen printing. When you need 50, 100, or 500+ matching shirts, screen printing delivers the best value.
Businesses and Brands — Employee uniforms, promotional giveaways, branded merchandise, and company events are all ideal for screen printing. The durable print ensures your brand looks professional wash after wash.
Sports Teams and Leagues — Team jerseys, practice shirts, fan merchandise, and league apparel are commonly screen printed because the prints hold up to the physical demands of athletic use and frequent washing.
Schools and Universities — Spirit wear, club shirts, Greek life apparel, orientation shirts, and graduation merchandise are all popular screen printing orders. ooShirts works with thousands of student organizations every year.
Merchandise and Resale — Bands, artists, content creators, and small businesses use screen printing to produce merchandise for sale. The low per-unit cost at higher quantities maximizes profit margins.
Understanding what affects screen printing pricing helps you make informed decisions about your order. Here are the primary factors that determine the cost of custom screen printed shirts:
Number of Ink Colors — Each color in your design requires a separate screen. More colors means more screens, more setup time, and more ink. A one-color design is the most affordable option, while designs with 4+ colors will cost more per shirt. At ooShirts, the $20 per-color setup is built into our pricing, so you always get an all-inclusive quote.
Order Quantity — Quantity is the single biggest factor in per-shirt pricing. Once the screens are created, printing additional shirts is fast and inexpensive. An order of 100 shirts will have a much lower per-shirt cost than an order of 12 shirts. The more you order, the more you save.
Garment Type and Brand — A basic cotton t-shirt costs less than a premium tri-blend tee or a heavyweight hoodie. The blank garment itself is a significant portion of the total per-shirt cost, especially on larger orders where the printing cost per shirt is minimal.
Number of Print Locations — Printing on the front only is the most common and affordable option. Adding a back print, sleeve print, or other additional location increases the cost because each location requires its own set of screens and setup.
Ink Type — Standard plastisol ink is the most common and affordable option. Specialty inks such as metallic, glow-in-the-dark, or discharge inks may carry a small additional charge due to the higher cost of the ink itself and the specialized handling required.
Screen printing and DTG (direct-to-garment) printing are the two most popular methods for producing custom t-shirts. Each has its strengths, and the best choice depends on your specific order:
Choose screen printing when: You are ordering 12 or more shirts, your design has 1–3 solid colors, you need prints on dark-colored garments, or durability is a top priority. Screen printing offers the lowest per-shirt cost at higher quantities and produces the most durable prints available.
Choose DTG printing when: You need fewer than 12 shirts, your design has many colors or photographic detail, or you want a soft hand feel with no texture on the print. DTG printing has no minimum order, no setup fees, and no extra charge for additional colors.
Not sure which method is right for your order? Use our online design tool to upload your design, enter your quantities, and get instant pricing for both printing methods. You can also contact our team for a free quote and expert recommendation.
Screen printed shirts are extremely durable and can last for many years with proper care. The curing process bonds the ink permanently to the fabric at high temperatures, creating a print that resists fading, cracking, and peeling. With normal washing and wearing, a properly screen printed design will typically outlast the garment itself. To maximize the lifespan of your screen printed shirts, wash them inside out in cold water and tumble dry on low heat or hang dry. Avoid using bleach or high-heat ironing directly on the print.
At ooShirts, the minimum order for screen printing is 12 shirts. This minimum exists because screen printing requires the creation of physical screens for each color in the design, and the setup time and materials make very small orders cost-prohibitive. If you need fewer than 12 shirts, we recommend DTG printing, which has no minimum order requirement — you can order as few as one shirt. For orders of 12 or more, screen printing will almost always be the more affordable option, especially as quantities increase.
Screen printing is not the ideal method for reproducing full-color photographs on t-shirts. Because each color requires a separate screen, photographic images with continuous tones and thousands of colors are not practical to screen print. However, a technique called simulated process printing can approximate photographic images using a limited palette of 6–8 ink colors with halftone dot patterns. For true photographic reproduction with unlimited colors and fine detail, DTG printing is the better choice. DTG uses inkjet technology to print directly onto the fabric with full CMYK color, making it capable of reproducing photographs with excellent detail and color accuracy.
