When budgeting for custom apparel projects, most people focus on the number of colors and quantity of garments but print size is one of the most important factors influencing cost. Whether you’re designing a logo for employee uniforms, event merchandise, or school apparel, understanding how print size affects pricing will help you make smarter, budget-conscious decisions.
In this article, we’ll break down why print size matters, how it impacts screen setup, production time, and ink usage, and what strategies you can use to get the most value out of your order. We’ll also highlight how ColorTex helps Ottawa businesses and event organizers optimize their designs for both impact and cost-efficiency.
1. The Basics of Screen Printing Pricing
Screen printing costs typically include:
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Screen setup fees: Each color requires its own screen, regardless of print size.
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Ink costs: Larger designs use more ink per garment.
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Production time: Bigger prints take longer to flash-cure and dry.
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Garment handling: Oversized prints require more precise placement, sometimes more labor.
While setup fees are fixed per color, print size directly influences ink usage and production time, which can significantly change your per-unit cost.
2. Standard vs. Oversized Prints
Standard Print Size
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Front Chest: Usually 8–10 inches wide
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Back Print: Usually 12 inches wide
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Sleeve or Pocket Print: 3–4 inches wide
Standard sizes are the most cost-effective because they fit within typical screen and press dimensions, requiring no special adjustments.
Oversized or Jumbo Prints
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Full Front or Back: Can cover almost the entire shirt
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Wrap-Around Prints: Extend across seams, requiring special press setups
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All-Over Prints: Require unique printing techniques and higher labor costs
Oversized prints use more ink and often require larger screens and additional press time, which adds to the overall cost.
3. How Print Size Affects Ink Usage
Ink is a major cost driver in screen printing.
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Larger prints = more ink per garment
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Specialty inks (metallic, puff, glow-in-the-dark) cost more and amplify the price impact of size
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Thicker deposits required for dark garments also add to cost
4. How Print Size Affects Production Time
Bigger prints take longer to flash-cure and dry because:
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More ink needs more heat to fully cure
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Printers may need to slow production to avoid smearing
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Large screens can be harder to align, adding to setup time
This increased production time may raise labor costs, particularly on small-to-medium runs.
5. Impact on Garment Selection
Not all garments accommodate large prints:
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Smaller shirts (youth or women’s cuts) may not have enough space for oversized designs
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Hoodies with zippers or pockets require special screen placement or split prints
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Stretch fabrics can distort large designs if not printed correctly
Planning your print size early allows you to select garments that work with your design and budget.
6. Cost Optimization Strategies
a) Adjust Design Size for Maximum Efficiency
Keep designs within standard print dimensions when possible to avoid oversized screen charges.
b) Consider Print Placement
Sometimes moving a design from a full front to a left chest print cuts costs significantly while still achieving branding goals.
c) Simplify Artwork
Less surface coverage means lower ink usage: a clean, minimalist design can look more modern and cost less.
d) Combine Multiple Elements Into One Print
If your design has multiple logos or text elements, consolidating them into a single print area can reduce setup fees and production time.
7. Balancing Visual Impact and Budget
It’s important to remember that bigger isn’t always better.
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A well-placed, proportionate print often looks more professional.
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Oversized prints can be uncomfortable for wearers, especially on warm days.
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Subtle prints can still be highly effective for corporate uniforms or premium merchandise.
The key is to align print size with the purpose of the garment: promotional giveaway shirts might justify larger designs, while staff uniforms often benefit from smaller, more discreet branding.
8. Example Cost Comparison
Print Size |
Approx. Ink Usage |
Production Time |
Relative Cost |
Left Chest (4") |
Minimal |
Fast |
$ |
Standard Front (9") |
Moderate |
Standard |
$$ |
Full Front (12–14") |
High |
Slower curing |
$$$ |
Wrap-Around/Jumbo |
Very High |
Longest setup & cure time |
$$$$ |
9. Spotlight on ColorTex: Helping You Optimize Print Size
ColorTex understands that budget and design must work together. Their team offers:
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Design Consultation: Helping clients resize or reformat artwork to minimize costs without sacrificing visual impact.
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Mockups & Proofs: Showing exactly how different print sizes will look on garments.
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Cost Transparency: Clear breakdown of how size affects pricing so clients can make informed decisions.
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Expert Recommendations: Suggesting alternative placements (sleeve, pocket, back yoke) to keep costs within budget.
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Specialty Printing Options: For clients who want oversized prints, ColorTex provides professional handling to ensure sharp, durable results.
By collaborating with ColorTex early in the design process, businesses and event organizers can strike the right balance between budget and brand visibility.
Conclusion
Print size is one of the most significant (and most overlooked) factors influencing screen printing costs. Larger prints use more ink, take longer to produce, and sometimes require specialized equipment, which can increase the price per garment.
The good news is that by planning ahead, using standard print sizes where possible, and working with an experienced partner like ColorTex, you can maximize the value of your project. With expert guidance, you’ll achieve the perfect balance between eye-catching design and cost efficiency.