Design dimensions and production settings
Ink type, mesh, and sell price
Cost Per Shirt
$0.25
50 shirts · 3 colors · Plastisol
| Mesh | Ink Deposit | Best For | Detail Level |
|---|---|---|---|
| 110 Mesh | 3 mil | Heavy ink, bold graphics on dark garments | Low |
| 156 Mesh | 2 mil | General purpose, good detail | Medium |
| 200 Mesh | 1.5 mil | Fine detail and halftones | High |
| 230 Mesh | 1 mil | Ultra-fine detail, process color (CMYK) | Very High |
Inputs
Result
A 10×12 inch print area through 156 mesh deposits 0.002 inches of ink per impression (2.0 mil). Each impression uses 0.133 oz of ink. At 50 shirts and 3 colors, total ink is 19.9 oz. At $20/quart plastisol, the ink cost is $12.47 total or $0.25 per shirt.
Inputs
Result
An 8×10 inch single-color print through 200 mesh uses just 0.066 oz per impression. With 200 shirts, total ink is 13.3 oz. Water-based ink at $26/quart (1.3x plastisol) costs $10.79 total or $0.054 per shirt. At $20 sell price, the ink-only profit margin is excellent.
Ink usage depends on print area, mesh count, and number of impressions. A 10×12 inch print with 156 mesh uses about 0.13 oz of ink per impression. For 50 shirts with 3 colors, you need roughly 20 oz total. Coarser meshes like 110 deposit more ink and use proportionally more.
| Mesh Count | Ink Deposit (mil) | Oz per 10×12" Print | Best For |
|---|---|---|---|
| 110 mesh | 3.0 mil | 0.20 oz | Bold designs on dark shirts |
| 156 mesh | 2.0 mil | 0.13 oz | General purpose printing |
| 200 mesh | 1.5 mil | 0.10 oz | Fine detail & halftones |
| 230 mesh | 1.0 mil | 0.07 oz | CMYK process color |
Use 110 mesh for heavy ink deposits on dark garments and bold designs. Use 156 mesh for general purpose printing with good detail. Use 200 mesh for fine detail and halftones. Use 230 mesh for ultra-fine detail and process color (CMYK) printing. Lower mesh numbers mean more ink deposit.
Ink cost per shirt is typically $0.15 to $0.50 depending on print size, colors, and ink type. Plastisol is cheapest at about $0.15 to $0.30 per shirt. Water-based ink costs 30% more and discharge ink costs 50% more. Total production cost including screens and labor adds $2 to $5 per shirt.
| Run Size | Cost Per Shirt (1 color) | Cost Per Shirt (4 color) |
|---|---|---|
| 24 shirts | $4.50–$6.00 | $7.00–$10.00 |
| 72 shirts | $2.50–$3.50 | $4.00–$6.00 |
| 144 shirts | $1.75–$2.50 | $3.00–$4.50 |
| 500 shirts | $1.25–$1.75 | $2.00–$3.00 |
Most screen printing businesses target a 50 to 70% profit margin on ink and materials alone. If ink costs $0.25 per shirt and you sell at $25, your gross margin on materials is over 98%. Real margins drop to 30 to 50% once you factor in labor, screens, emulsion, and overhead.
Plastisol ink is the industry standard and cheapest option at about $20 per quart. Water-based inks cost 30% more but give a softer hand feel. Discharge inks cost 50% more and remove garment dye for a bleach-like effect on dark shirts. Each type has different curing requirements.
| Ink Type | Cost/Quart | Hand Feel | Cure Temp |
|---|---|---|---|
| Plastisol | $18–$25 | Raised/rubbery | 320°F |
| Water-based | $25–$35 | Soft/no feel | 300°F |
| Discharge | $30–$40 | Ultra-soft | 320°F |
| Silicone | $40–$60 | Stretchy/smooth | 300°F |
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Last Updated: Mar 9, 2026
This calculator is provided for informational and educational purposes only. Results are estimates and should not be considered professional financial, medical, legal, or other advice. Always consult a qualified professional before making important decisions. UseCalcPro is not responsible for any actions taken based on calculator results.