← All articles · 2026-06-24

What are the hidden costs of custom shirts?

Short answer: The seven most common hidden costs are setup/screen fees ($20–35 per color, per side), per-color ink charges ($1–3 per shirt), 2XL+ size upcharges, rush fees, customs duties, art/digitizing fees, and shipping added at checkout — together they can inflate a quote 20–40%.

The sticker price on a custom shirt is rarely the price you pay. Here are the add-ons that show up later, and how to avoid each.

The 7 hidden costs

1. Setup / screen fees — A one-time charge of about $20–35 per ink color, per side to burn each screen. A three-color front plus one-color back can add ~$100 before any shirts print. Avoid it: choose a printer that charges $0 setup.

2. Per-color ink charges — Many printers bill $1–3 per ink color, per shirt, so a five-color design quietly multiplies your decoration cost across the whole order. Avoid it: use full-color printing with no per-color charge.

3. 2XL and plus-size upcharges — Larger sizes often carry a per-shirt surcharge, which inflates orders with a wide size range. Avoid it: order where mixed sizes (youth through adult plus) all count at one price.

4. Rush fees — Need it fast? Expedite charges commonly run 15–30% extra. Avoid it: plan about three weeks ahead so standard production covers your date.

5. Customs duties and brokerage — On imported orders, a surprise duty bill or broker fee can hit at the door. Avoid it: order delivered-duty-paid (DDP), where duties are included and there’s no separate customs bill.

6. Art / digitizing fees — Some shops charge to prep your file or digitize a logo for embroidery. Avoid it: use a service that includes free design and mockup.

7. Shipping added at checkout — A low per-shirt price can hide freight tacked on later. Avoid it: get an all-in delivered price up front.

How much these add up to

Hidden cost	Typical impact	Avoidable?
Setup / screen fee	$20–35 per color/side	Yes ($0 printers)
Per-color ink	$1–3 per color/shirt	Yes (full-color, no per-color)
2XL+ upcharge	Per-shirt surcharge	Yes (one-price sizing)
Rush fee	+15–30%	Yes (plan ahead)
Customs duties	Varies	Yes (DDP)
Art / digitizing	One-time fee	Yes (free mockup)
Shipping at checkout	Freight	Yes (all-in price)

How Togethread removes them

We quote one all-in price with the hidden costs designed out: $0 setup, no per-color charge, mixed sizes at one price, free design and mockup, and delivery duty-paid to your door with no customs bill. The main thing you do on your side is plan about three weeks ahead so you never need a rush fee. A real designer sends your free mockup within 24 hours; you approve before paying and see finished photos before the balance.

FAQ

What’s the most common hidden cost in custom shirt orders? Setup/screen fees and per-color ink charges — together they can add the most, especially on small or multi-color orders.

Do plus sizes really cost extra? At many printers, yes — 2XL and larger carry a per-shirt upcharge; some services instead count all sizes at one price.

How do I avoid a customs bill on imported shirts? Order delivered-duty-paid (DDP), where duties and import handling are included in the quoted price, so nothing is billed at your door.

Related: Custom t-shirt setup fees explained, Is it cheaper to order custom shirts overseas?, Custom company shirts in bulk

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