Why Custom Embroidery Costs More — and How Bulk Saves

 

Have you ever wondered why it feels expensive to embroider just one polo or jacket? At first glance, it seems simple: one shirt, one logo. But behind the scenes, every order goes through a process that is closer to manufacturing than retail. That’s why a custom project isn’t priced like grabbing a polo from a store rack.

One-Offs vs. Mass Production

Retail brands like Ralph Lauren or Nike produce in the tens of thousands. The embroidery file, machine setup, and thread colors are prepared once and then repeated on bulk runs. Their production cost per item drops dramatically because the setup expense is divided across thousands of garments. That’s how they can sell one retail polo at a “reasonable” price.

Custom orders work differently. When you place a single order through a decorator, your artwork is digitized, machines are threaded, and placement is tested exclusively for your logo. The labor involved is nearly the same whether you’re ordering one or 100 items. That’s why small runs appear more costly.

Even Overseas, One Piece Is Still a Sample

Some buyers think they can save by ordering from factories in China. The truth is, even internationally, one or two pieces are considered “samples”. Factories charge extra for samples, not less. On top of that:

• Air freight with UPS, FedEx, or DHL adds significant cost.
• Ocean shipping can take 30–60 days, making it impractical for most projects.
• Customs and logistics fees can wipe out any savings.

For anything under large-scale production, it’s more efficient to work with a local partner like Inkdnylon Custom Apparel.

Transparent Pricing at Inkdnylon

To make embroidery simpler and fair, Inkdnylon offers one of the clearest pricing models in the industry:

• $5 flat rate for embroidery up to 5 inches
• $2.50 for each additional inch

See details here: Contract Embroidery.

Support for Distributors

Inkdnylon also provides wholesale-level embroidery through ASI, SAGE, and PPAI. Distributors and resellers can pass on cost savings while relying on high-quality decoration. More info here: Distributor Embroidery Pricing.

Beyond Embroidery

Branding isn’t limited to thread. Inkdnylon also offers:

• Screen Printing for larger runs
• Direct-to-Film (DTF) transfers for vibrant detail
• Vinyl names and numbers
• Rhinestones and spangles for sparkle
• Patches in embroidery, leather, PVC, or chenille
• Sublimation for full-color edge-to-edge designs

Want to dive deeper into the topic? Check out the full article on our Shopify blog: Why Custom Branding Apparel Seems Expensive (and How Bulk Saves Money) .

The Smart Way to Save

The key to saving on branded apparel is volume. Small runs will always feel expensive because setup is spread across fewer items. But when you plan ahead and order in bulk, your cost per piece drops quickly while your brand presence grows stronger.

Want to compare? Read the full Shopify blog version here: Why Custom Branding Apparel Seems Expensive (and How Bulk Saves Money).

Start today: Instant Quote | Contract Embroidery | Distributor Pricing