How to Order Custom T-Shirts in Bulk: A Step-by-Step Guide

Ordering 50, 100 or 500 custom shirts sounds simple until you're juggling a design file, a size spreadsheet and a deadline. Whether it's for a chapter, a club, a company or an event, the process is the same. Here's how to do it without surprises.

Step 1: Decide what you're making and why

Write down three things before you talk to a printer: who's wearing it, when they need it, and roughly what you can spend per shirt. That answer shapes every other choice, from the blank to the print method.

Step 2: Get your design ready (or get help)

If you already have artwork, send the highest-quality version you have. Vector files (AI, EPS, SVG or PDF) are ideal. If all you have is an idea, a sketch or a few screenshots, that's fine too. Many shops will design it for you. Threadz design requests are free, and you'll get a proof to approve before you pay anything.

Step 3: Choose a blank shirt

The shirt matters as much as the design. Heavier, garment-dyed tees like Comfort Colors feel premium and get worn again. Lighter, fitted tees like Bella+Canvas look modern. Budget tees like Gildan keep big giveaway orders affordable. We compare them in detail in this guide to choosing blanks.

Step 4: Pick the right print method for your quantity

Screen printing: the best value for larger orders, especially with a few ink colors. Most shops have a minimum (ours is 48 pieces).
DTF (direct to film): great for small orders and full-color designs, with no minimum.
Embroidery: polished and durable, best for polos, hats and left-chest logos.

Not sure? Here's our breakdown of screen printing vs. DTF vs. embroidery.

Step 5: Collect sizes the easy way

Use a simple form with a hard deadline, share the size chart, and order a few extras in the most common sizes. If everyone is paying for their own shirt, skip the spreadsheet entirely and use an online store where people pick their own size and pay directly.

Step 6: Understand what affects the price

Bulk shirt pricing mostly comes down to:

The blank you choose
How many shirts you order (more shirts, lower price per shirt)
How many ink colors and print locations (front, back, sleeve)
Extras like names, numbers or specialty inks

Two well-chosen colors on a great blank usually beat a six-color design on a cheap shirt.

Step 7: Approve the proof carefully

Check spelling, dates, colors, print size and placement. Once you approve, production starts and changes get expensive.

Step 8: Plan your timeline backward

Start from the day you need shirts in hand and work back: shipping, production, proof approval, design. Starting four to six weeks out keeps you out of rush territory.

Ready to start? Send a free design request, then place a bulk order or request an online store once you love the proof.