Quick Answer
How Much Does It Cost to Make T-Shirts for a Family Reunion?
Custom reunion T-shirts typically cost $8–$18 per shirt for orders of 50+. Ordering 100+ drops price to $7–$12. Budget $12–$15 per shirt including design fees for a realistic estimate.
Price Breaks by Order Quantity
T-shirt printing is one of the clearest examples of bulk pricing — the per-shirt cost drops significantly as your order size grows. Here are realistic price ranges from major online print shops:
Prices above are for standard cotton tees (Gildan, Bella+Canvas, or equivalent). Premium blanks (tri-blend, performance fabric) add $3–$8 per shirt. Shipping is extra and varies by vendor and location.
The All-In Cost: Don't Forget These Add-Ons
- Design fee: $0 (DIY with Canva) to $150–$400 (professional designer)
- Setup fee: $25–$75 per color/screen at traditional screen printers
- Shipping: $0.50–$2/shirt depending on quantity and distance
- Rush order fee: 20–50% premium for orders needed in under 2 weeks
- Oversized sizing (2XL+): $2–$4 per shirt upcharge, plan for 10–15% of your order
- Back printing: $2–$5 per shirt for a second print location
How to Save Money on Reunion T-Shirts
Order early (6–8 weeks out)
Avoid rush fees that add 20–50% to the price. This is the single biggest money-saver.
Keep the design simple
1–2 color designs cost significantly less than full-color or multi-location prints. A family name, year, and simple graphic is all most shirts need.
Collect sizes upfront
Ordering the wrong size mix means leftover shirts and extra cost. Use Reunly to collect shirt sizes when guests register.
Order 5–10% extra in medium and large
The most common sizing mistake is running out of medium and large. Order extra in those sizes; you can sell extras or keep them.
Use an online bulk printer
CustomInk, 4imprint, and similar sites are typically cheaper than local print shops for orders over 50 shirts.
Charge shirts separately
Some families make shirts optional and charge exactly the per-shirt cost. This avoids subsidizing shirts for guests who won't wear them.
Should T-Shirts Be Included in Registration or Optional?
Including T-shirts in the registration fee is simpler to manage but means everyone pays for a shirt whether they want one or not. Making shirts optional and charging the actual cost per shirt ensures no one subsidizes another's shirt — but it requires tracking size orders separately.
Reunly lets guests indicate shirt size (and whether they want one) when they register, so you have a complete size count before you ever place the order. No more size guessing or last-minute scrambles.
Building T-Shirts Into Your Budget
For a 75-person reunion ordering 80 shirts (including a few extras) at $11/shirt all-in, T-shirts cost about $880 — roughly $11.75 per attending adult. Add this to your registration fee calculation in Reunly's budget calculator to see exactly what it adds to your per-person price.
🚀 With Reunly
Track every dollar with Reunly's free budget tool
Budget categories, payment tracking, and per-person cost calculator — all in one place.
Collect shirt sizes when guests register
Reunly tracks guest details, shirt sizes, and payments in one place — so ordering T-shirts is one less headache.
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