Screen printing for Reno t-shirt orders
Screen print is the cheapest way to put a design on 48 or more tees, and a cured plastisol print outlasts the shirt. Battle Born Clothing prints in-house in Yerington, Nevada with plastisol, water-based and discharge inks on a conveyor dryer. No hard minimum; 48 pieces and up is where it makes sense.
What it costs
| Job | Print per piece | PC61 all-in | Screens (one-time) |
|---|---|---|---|
| 1 color, 1 location, light shirt | $4.34 | $10.38 | $20 |
| 1 color, 1 location, dark shirt (flash) | $4.59 | $10.63 | $20 |
| 1 color front + 1 color back, light shirt | $8.68 | $14.72 | $40 |
| 1 color front + 1 color back, dark shirt | $9.18 | $15.22 | $40 |
On a $6.04 Port & Company PC61 that makes a black tee with a 1-color front print $10.63 each at 48, plus a $20 screen, and $15.22 with a 1-color back added, plus $40 in screens. Two ink colors on the front means two screens ($40 for the front alone) and a per-piece rate quoted for the job. Worked totals are on the pricing page.
Inks: plastisol, water-based, discharge
- Plastisol: the standard. Opaque, bright, sits on top of the fabric. Works on cotton, blends and polyester. Our default for company and event tees.
- Water-based: soaks into the fiber for a soft hand. Best on light 100% cotton. The usual pick for brewery and coffee merch.
- Discharge: removes the shirt dye and replaces it with ink color. Softest result on dark 100% cotton like the Comfort Colors 1717. Not for blends, tri-blends or polyester.
The flash charge, explained
On a dark shirt we print a white underbase and flash-cure it before the top color so the logo stays bright instead of muddy. That is the $0.25 per flash per location on the invoice. On a white, ash or safety-color shirt it is usually not needed, so a light shirt is $0.25 cheaper per location.
When screen print is the wrong tool
- Under about 48 pieces: screens cost the same for 12 shirts as for 120, so the per-shirt price climbs. DTF is usually cheaper.
- Photos, gradients, 4+ colors: DTF.
- One logo that needs to look like a uniform: embroidery.
Artwork we need
- Vector (AI, EPS, PDF, SVG) is best. A 300 dpi PNG at print size works.
- One file per ink color is not required; we separate colors. Tell us the ink colors by Pantone or by naming them.
- Front logo is usually 3.5-4 inches wide left chest or 10-12 inches wide center chest. Back prints are 10-12 inches wide.
- Keep text at least 0.25 inches tall. See artwork prep.
Questions
Is there a minimum for screen printing?
No hard minimum. We recommend 48 or more because the screens cost the same whether you print 12 shirts or 120.
Can I mix shirt colors and sizes in one run?
Yes, as long as the ink colors stay the same. Mixing light and dark shirts adds the flash on the darks only. Sizes do not change the print price; 2XL and up carry the supplier upcharge on the blank.
Do you keep my screens?
We keep your artwork and separations. Screens are reclaimed and rebuilt at $20 each on a reorder.