How to order custom merch in small quantities

A small shop can order branded shirts, totes or stickers without filling a stockroom. The route depends on how many pieces you need, which decoration suits the design, and how much time you have before the items must arrive. This guide walks through each decision in order.

Print on demand or a bulk order

There are two common ways to buy small batch merch. Each suits a different situation.

• Print on demand: the supplier makes each item after an order comes in. You hold no stock, and you can order a single piece. Print on demand merch suits a test run, an online shop or a design you are not sure about.
• Bulk order: a decorator produces a batch to your order. You hold the stock, and the price per piece usually falls as the quantity rises. Vistaprint's clothing and bags page says its price per unit goes down as you add more items.

A uniform order for a known team size often fits a bulk order. A tote you hope to sell may fit print-on-demand ordering until you see how it sells.

What a minimum order quantity means

A minimum is the smallest number of pieces a supplier will make for one design. It varies by product and by method, so check it on the product page rather than assuming.

Examples from vendor pages:

• Bonfire says it has no minimums for custom products, because it prints on demand.
• Vistaprint says many of its custom clothing products are available at a minimum quantity of one.
• MOO says the minimum for its stickers varies with the sticker size.

Sellers that offer custom merch no minimum are usually print-on-demand services such as Printful and Printify. Compare the per-piece price with a bulk quote before deciding.

Choose a decoration method

The method affects how many colors you can use, how the print feels and which items it suits. Vistaprint's clothing page lists screen printing, direct-to-garment, heat transfer, dye sublimation and embroidery.

• Screen printing: ink is forced through a mesh screen onto the item. A stencil blocks the areas that should stay clear (Tate).
• Direct-to-garment (DTG): Printful describes it as ink sprayed onto garments, much like printing on paper. It suits complex, multi-color designs.
• Embroidery: the logo is stitched into the fabric with thread.
• Heat transfer and cut vinyl: a printed or cut film is pressed onto the fabric with heat.

Screen printing vs DTG

Screen printing needs a screen and stencil prepared before the run, so it fits batches of the same design. DTG prints from a digital file, and Printful's DTG page offers it for print-on-demand orders with no order minimums. Vistaprint lists its screen printing at one print color and its DTG at unlimited colors. If your logo has fine gradients or a photo, ask how each method will reproduce it.

Embroidery vs screen printing

Embroidery gives a raised, textured logo that suits aprons, polo shirts and caps. It works best with a simple mark, since fine text may not stitch cleanly at small sizes. Screen printing suits larger areas such as the back of a shirt. Ask the supplier which method fits the garment and the size of the logo.

Check the mockup and the proof

A merch mockup is a picture of your design on the product. It helps you judge size and placement. Printify says you can check designs in mockups and order samples before listing products.

A proof is the supplier's final layout before production. Read it as the item that will be made: check spelling, colors, size, placement and the quantity of each size. Sticker Mule's custom stickers page says its print proof shows the exact sizing and pricing, and that you can request size changes during proofing. Approve only when every detail matches what you want.

Order a sample first

A screen shows color and placement. It does not show fabric weight, print feel or how the item survives washing. Request a sample when the item is new to you, when staff will wear it every day, or when you plan to sell it. Some suppliers offer samples of promotional products, as 4imprint does.

Wear or use the sample for a few days, wash it if it is clothing, and note any change before you approve a larger run.

Plan the lead time

Work back from the date you need the items, and allow time for each step:

1. Prepare the artwork in the format the supplier asks for.
2. Review the mockup and request changes.
3. Approve the proof.
4. Receive and test a sample.
5. Wait for production of the full order.
6. Allow for shipping, plus a buffer for a reprint.

Each vendor states its own production and shipping times on its site, and they differ by product and method. A print-on-demand campaign can add its own window: Bonfire's sell online page says its campaigns collect pre-orders for up to 21 days before printing.

Labels on shirts you sell

Clothing you sell to customers carries rules that uniforms may not. The FTC care labeling rule covers manufacturers and importers of textile wearing apparel, including anyone who directs or controls the manufacture (16 CFR 423.4). Ask the supplier how care labels are handled before you list shirts for sale.

For ideas on which items to order, see the guide to branded merchandise for small shops.

Frequently asked questions

Is print on demand cheaper than a bulk order?

It depends on the quantity. Print on demand avoids paying for stock you may not sell, while a bulk order usually lowers the price per piece. Get both quotes for the quantity you expect to need.

Can I order one shirt with my logo?

Some suppliers allow it. Vistaprint says many of its clothing products are available at a minimum quantity of one, and print-on-demand services make items one at a time.

What file should I send?

Ask the supplier which formats it accepts. A clean, high-resolution logo gives the decorator the most to work with.

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