Let's be honest, ordering custom t-shirts in bulk should save you money, not drain your budget. But if you're like most people, you've probably made at least one (or all seven) of these costly mistakes that turn what should be a great deal into an expensive headache.
Whether you're planning team shirts for your startup, organizing a charity event, or launching your first merch line, these mistakes can easily cost you hundreds of extra dollars. The good news? They're totally avoidable once you know what to watch out for.
Mistake #1: Paying Retail When You Could Go Wholesale
This is probably the biggest money-waster out there. Walking into Target or a local print shop and paying $15-25 per shirt when you need 25 pieces is like throwing money out the window. Most people don't realize that wholesale pricing kicks in way sooner than you'd think, sometimes as low as a dozen shirts.
Here's the reality check: that "great deal" you found at a big box store is still retail pricing. Real wholesale deals exist, and they can cut your per-shirt cost in half or more.
The fix: Always get quotes from multiple suppliers before buying. A legitimate wholesale deal should feel almost too good to be true. For example, our 25 full-color custom printed shirts for just $199 works out to under $8 per shirt, that's the kind of pricing that makes bulk orders actually worth it.
Mistake #2: Choosing the Wrong Fabric for Your Audience
Nothing kills a bulk order faster than getting fabric that your audience hates. I've seen businesses order heavy cotton shirts for outdoor summer events (hello, sweaty disaster) or go with cheap, scratchy materials that people refuse to wear.
The worst part? You're stuck with 25, 50, or 100 shirts that nobody wants. Your cost per useful shirt just went through the roof.
The fix: Think about when and where people will wear these shirts. Gym fundraiser? Go for moisture-wicking blends. Corporate event? Stick with comfortable cotton or cotton blends. Team uniforms? You want something durable that holds up to washing.
The key is having options. When we offer multiple shirt styles and colors, you can pick what actually makes sense for your specific situation instead of being stuck with whatever's cheapest.
Mistake #3: Guessing Your Size Mix (And Guessing Wrong)
Here's a classic: ordering 5 smalls, 5 mediums, 5 larges, 5 XLs, and 5 XXLs because it seems "balanced." Then you end up with a pile of smalls and XXLs that nobody wants while running out of mediums and larges on day one.
This mistake turns your cost-effective bulk order into expensive leftover inventory that sits in your closet for years.
The fix: Use the 70-20-10 rule as a starting point. About 70% of your order should be sizes M, L, and XL (with L being the most popular), 20% should be S and XXL, and 10% should be XS and XXXL+. Adjust based on your specific audience, but this ratio works for most groups.
Mistake #4: Waiting Until the Last Minute
"Oh crap, the event is next week and we still need shirts!" Sound familiar? Rush orders are budget killers. When you're desperate, you'll pay whatever it takes, and suppliers know it.
Plus, when you're rushed, you make more mistakes with design files, sizing, and quantities. Each fix adds time and money to your order.
The fix: Start planning your shirt order at least 2-3 weeks before you need them. This gives you time to get samples, make adjustments, and avoid rush fees. Many suppliers offer better deals when they can fit your order into their regular production schedule.
Fast shipping can help bridge the gap when you do plan ahead. That's why we include fast, free shipping in our deals, so you can plan appropriately without worrying about surprise shipping costs eating into your budget.
Mistake #5: Ordering Exactly What You Need (No Buffer)
Let's say you need exactly 25 shirts for your team. So you order… exactly 25 shirts. Then Murphy's Law kicks in: one shirt has a printing error, someone new joins the team, or you realize you want a few extras for future team members.
Now you're placing a tiny reorder for 2-3 shirts, paying setup fees and small-quantity pricing that can cost more per shirt than your original bulk order.
The fix: Always order about 10% more than you think you need. For a 25-person team, order 28-30 shirts. These extras serve as replacements for defects, additions for new team members, or backups for future events. The small additional cost is insurance against expensive emergency reorders.
Mistake #6: Sending Terrible Design Files
Your logo looks great on your business card, so you right-click, save it, and send that tiny 72-DPI image to your printer. The result? Pixelated, blurry prints that make your brand look unprofessional.
Or maybe you spent hours creating the perfect design in Word or PowerPoint (cringe), only to discover that your printer can't use those file types and the fonts you chose aren't available.
The fix: Use vector files (AI, EPS) or high-resolution PNGs (at least 300 DPI at print size). If you don't have design files in the right format, many suppliers offer design services or easy-to-use online design tools that help you create print-ready artwork without the guesswork.
Our online designer tool lets you upload your logo, add text, and see exactly how your design will look on the shirt before you order. No surprises, no pixelated disasters.
Mistake #7: Skipping the Sample Step
This is the mistake that hurts the most because you don't discover it until after you've committed hundreds of dollars. The shirts feel different than expected, the fit is weird, the color is off, or the print quality isn't what you imagined.
With a bulk order of 25+ shirts, that's a expensive lesson in why samples exist.
The fix: For your first order with any supplier, get a sample. Many companies offer sample programs or small test orders specifically for this purpose. Yes, it adds a few days to your timeline, but it prevents disasters that cost way more time and money to fix.
The Smart Way to Order Bulk T-Shirts
Here's how to avoid all seven mistakes in one go: find a supplier who offers transparent pricing, multiple options, quality guarantees, and good customer service.
Our 25 full-color custom printed shirts for $199 deal hits all these points:
- Real wholesale pricing that saves you hundreds compared to retail
- Multiple shirt styles and colors so you can pick what works for your audience
- Online design tools that ensure your files are print-ready
- Fast, free shipping so you don't have to rush your order
- Full-color printing included in the price (no surprise color fees)
The best part? You know exactly what you're paying upfront. No hidden fees, no surprise charges, no "oh, by the way" costs that show up later.
Your Next Step
Don't let these seven mistakes drain your budget on your next bulk order. Whether you're ordering team shirts, event merchandise, or promotional apparel, a little planning goes a long way toward getting exactly what you need at a price that makes sense.
Ready to see how much you can save? Check out our 25-shirt deal and use our online design tool to see exactly how your shirts will look before you commit. Your budget (and your team) will thank you.