How much merch should I order for a pop-up or event, and which print method?

Estimate the quantity from your audience

Start with how many people will walk past the table and what share of them have bought from you before. Past sales at a similar event are the best guide you will ever have; if this is the first one, order conservatively, sell out, and treat the sell-out as data for the next order. Leftover stock in the wrong sizes is the most expensive outcome, because it ties up cash and storage.

Remember the reorder works in your favor. We keep your artwork and stitch files on file, so reorders are quick, and a screen-print reorder of the same design carries no setup.

Fewer designs, deeper

Every design is its own run. One design at 72 pieces prices far better per shirt than two designs at 36 each, and three designs split below 36 would each fall under the screen printing line. The volume tier is set by the total pieces on the order, so a multi-design order still benefits from its overall size, but each design needs 36 pieces of its own to run on screens.

A practical pattern: one or two core designs on screen printing, plus a small limited design on DTG to see what sells.

Which method for which item

• Screen printing: the main tees and hoodies, from 36 pieces per design. Lowest price per piece at volume and the most durable print.
• DTG: limited drops, test designs and full-color art, with no minimum and no setup fee.
• DTF transfers: from 12 pieces, for full-color art on fabrics DTG does not suit, such as polyester and nylon.
• Embroidery: hats and beanies, from 24 pieces per design.
• Heat transfer vinyl: names, numbers and simple one-color text, from 6 pieces.

Size curve and timing

For a general adult crowd, most of the run belongs in medium, large and extra large, with smaller amounts of small and 2XL and only a few of the extended sizes, which also carry a size upcharge on the blank. If your audience skews one way, follow your own sales history over any rule of thumb.

Standard turnaround is about 2-3 weeks after the artwork is approved and the deposit is paid. Rush depends on the schedule, so tell us the event date in the first message. The clock starts at proof approval, so approve in one pass.