How Much Do Custom Polo Shirts Cost?

Custom polo shirts are more popular than ever. But the simple question of "How much do polo shirts cost?" doesn't have a simple answer. That's because pricing varies dramatically based on factors like shirt quality, decoration method, order size, and several other variables. We're here to break down every cost factor so you can budget accurately and make smart choices for your specific needs. Let's jump into it.

The Short Answer: Average Price Range

Custom polos typically cost between $18 and $80 per piece, with most orders averaging around $30. That wide range reflects the massive variety in products and customization options available. A basic cotton polo with simple embroidery from a budget brand might hit the low end, while a premium performance polo with multiple decoration locations can easily reach the upper range. Variables like order quantity, shirt brand, fabric type, decoration method, and design complexity all play major roles in determining your final cost.

We organize polo shirts into three pricing tiers to help you navigate options. Budget polos range from $18-25 (averaging $20), offering solid quality for cost-conscious buyers. Midrange polos fall between $25-50 (averaging $30), delivering better fabrics and construction for most business needs. Premium polos span $50-80 (averaging $60), featuring top-tier brands, performance materials, and superior construction for upscale applications.

Factors That Affect the Cost

Understanding polo shirt pricing means breaking down the individual elements that drive costs up or down. Each factor below can significantly impact your final price per piece, and they often interact with each other in ways that aren't immediately obvious. Let's examine what really matters when pricing your custom polo order.

1. Shirt Type

The foundation of your polo's cost starts with the shirt itself. Basic cotton polos use traditional pique knit fabric—that textured, breathable weave you see on classic golf shirts. These represent the most affordable option and work well for most business applications. Performance polos step up with moisture-wicking polyester or poly-cotton blends, designed for active wear or outdoor work environments. You'll also find specialty options like long-sleeve polos, women's fitted cuts, and sporty golf shirts with advanced fabric treatments.

Fabric weight and construction quality vary significantly across types. Budget cotton polos might use 5.5-6 oz fabric, while certain premium options can offer 7-8 oz for a more substantial feel. Performance fabrics bring additional features like UV protection, anti-microbial treatments, and pill resistance, but these technologies add to manufacturing costs and reflect in the final price.

Example: The Harriton Ringspun Cotton Pique Polo (M200) uses 100% cotton construction, and 50 pieces with embroidery costs $21 each. The Devon & Jones CrownLux Performance™ Address Melange Polo Shirt (DG22) jumps to $37 each for the same order, featuring 4.9 oz. 100% polyester cotton-feel birdseye mesh fabric that offers superior moisture-wicking and UV protection performance.

2. Brand Quality

Brand selection dramatically impacts your polo pricing, often more than fabric type alone. Premium brands like Nike, Under Armour, and Peter Millar command higher prices due to their reputation, quality standards, and brand recognition. Midrange brands such as Sport-Tek, OGIO, and Port Authority offer solid construction and performance features without the premium brand markup. Budget brands like Gildan, Jerzees, and Team 365 focus on value pricing while maintaining acceptable quality for most applications.

Brand pricing isn't always straightforward—many manufacturers offer products across multiple price tiers. Nike makes both affordable basic polos and high-end performance shirts, while budget brands occasionally produce premium lines that compete with mid-range options. The brand name itself carries value, especially for customer-facing staff or retail merchandise where logo recognition matters.

Example: The Gildan DryBlend® Jersey Sport Polo (G880) costs $23 each for 50 pieces embroidered, while the TravisMathew Oceanside Heather Polo (TM1MU412) runs $107 each for the same order. Both feature cotton-poly blends, but the quality construction and brand prestige account for the significant price difference.

3. Customization

Embroidery remains the go-to decoration method for polo shirts, delivering that professional, upscale look that complements the garment's business-casual nature. The raised, textured finish of embroidered logos adds perceived value and durability that customers expect on polo shirts. However, screen printing or DTF (Direct-to-Film) transfers work better on thin, lightweight performance fabrics where embroidery might pucker or distort the material. These printing methods also handle complex, multi-color designs more cost-effectively than embroidery.

Embroidery pricing operates on stitch-count—larger designs and more colors mean more stitches, which translates to higher costs. Simple text or small logos stay affordable, while intricate artwork or oversized designs can significantly bump up your per-piece price. Screen printing and DTF use color-based pricing, but are still more suitable for designs with multiple colors or gradients that would be expensive or difficult to successfully embroider.

Example: The Devon & Jones CrownLux Performance™ Plaited Polo Shirt (DG20) with 50 pieces and 1-color screen printing costs $27 each, while the same shirt with embroidery runs $32 each. Keep in mind that embroidery pricing scales with stitch count and color quantity, which can increase costs further.

4. Number of Print Locations

Adding multiple decoration locations multiplies your customization costs since each location requires separate setup and production time. Most polo orders stick with a single left chest embroidery—the classic, professional placement that works for virtually any application. However, upscale branding opportunities exist with additional small logos on sleeves or upper back collar areas. Work uniforms often benefit from personalization like employee names on the right chest, creating a polished, professional appearance.

Each additional location adds both setup costs and per-piece decoration fees. The math is straightforward: two locations roughly double your decoration expense, three locations triple it, and so on. Consider whether the extra branding impact justifies the increased cost, especially for large orders where the additional expense compounds quickly.

Example: The Port Authority Silk Touch Polo (K500) with single embroidery location costs $24, while adding a second location brings the price to $32—a $8 increase per shirt that adds up significantly across larger orders.

5. Order Quantity

Bulk ordering delivers the most significant cost savings in custom apparel, and polo shirts follow this industry standard. Most printing companies use tiered pricing with arbitrary breakpoints—you might pay one price for 1-71 shirts, then suddenly get a discount at 72 pieces. This forces customers to order more than needed just to hit the next price tier. We use rolling volume pricing instead, giving you incremental discounts on each additional item you order, so you're never penalized for ordering the exact quantity you need.

Embroidered polos require a 6-piece minimum order due to setup costs, while printing allows single-piece orders (though at higher per-unit costs). The sweet spot for most businesses falls between 25-100 pieces, where volume discounts become substantial but quantities remain manageable. Ordering in bulk not only reduces per-piece costs but also ensures color consistency across your entire order.

Example: The Nike Dri-FIT Vertical Mesh Polo (637167) costs $73 at the 6-piece minimum, drops to $63 (14% savings) when you order 30, and falls to $55 at 100 pieces—a 25% discount that makes bulk ordering the smart financial choice.

6. Shirt Sizes

Larger sizes cost more due to the additional fabric and materials required for production. Most polo shirts maintain consistent pricing from Small through XL, but 2XL and above typically carry upcharges. Some products extend to 4XL or even 5XL, with costs increasing at each size level. Custom youth polos often cost less than adult sizes, reflecting their smaller material requirements.

Size pricing usually balances out across typical orders since most groups need a mix of sizes. However, if you're outfitting a team or workforce that skews toward larger sizes, expect your overall order cost to increase. The upcharges aren't massive on individual pieces, but they add up when ordering dozens of 2XL+ shirts.

Example: Size upcharges vary between brands and products, so you'll need to check the specific pricing when placing your order. Generally, it's not a significant factor unless you're ordering predominantly larger sizes—then those extra dollars per shirt can impact your budget.

7. Colors & Complexity of Design

Printing costs scale directly with the number of colors in your design. Screen printing requires a separate screen for each color, increasing setup time and material costs. Embroidery pricing depends on both design size and color count, which translates to total stitch count—more stitches mean higher costs. Once you upload your design and submit your order, you'll receive an accurate quote based on these factors.

Our art department provides free assistance if you need to reduce size, complexity, or color count to meet your budget. Special effects like puff embroidery, tackle twill, or ombre colors carry additional charges. Printing offers more straightforward pricing with slight upcharges for each additional color, making it worth considering whether you really need all those colors in your design, especially for screen printing where costs compound quickly.

Example: The Core 365 Origin Performance Piqué Polo (88181) with one-color printing on 50 pieces costs $23 each. Jumping to 8-color screen printing increases the price to $34 each—nearly a 50% increase that shows how much color choice can impact your budget.

8. Turnaround Time & Shipping

Most printing companies charge extra fees based on how quickly you need your order completed. We're known for fast turnaround times across all orders, with free standard shipping to anywhere in the contiguous United States—delivery expected within 9-12 business days. This standard timeline works for most customers and keeps costs down since you're not paying rush fees.

When deadlines get tight, we offer rush shipping with guaranteed delivery as fast as 2 business days, though this service carries additional charges. We even provide next-day shipping for select products and services when you absolutely need it yesterday. We also ship to Canada and US APO/FPO locations, with international shipping available in some situations.

Tips for Saving Money

• Order in bulk when possible: Volume discounts provide the biggest cost savings in custom polo orders. Even jumping from 6 pieces to 30 can save 10-15% per shirt, while orders of 100+ unlock substantial discounts that make bulk purchasing the smart financial choice.
• Stick to single custom locations: That classic left chest embroidery delivers professional results without the added expense of multiple locations. Unless you need extensive branding or employee names, one well-placed logo typically provides all the impact you need.
• Choose standard materials over performance fabrics: Basic cotton pique polos work perfectly for office environments, retail staff, or indoor events. Save performance fabrics for teams that actually need moisture-wicking properties or outdoor work crews.
• Select budget or mid-range brands strategically: Gildan, Port Authority, and Sport-Tek deliver solid quality for most business applications. Reserve premium brands like Nike or Peter Millar for customer-facing roles, executive teams, or retail merchandise where brand recognition adds value.
• Plan ahead to avoid rush fees: Our free standard shipping (9-12 business days) costs nothing extra and works for most deadlines. Rush orders can double your shipping costs, so planning even two weeks ahead saves significant money.
• Keep designs simple: Single-color embroidery or printing costs far less than complex, multi-color artwork. A clean logo or text design often looks more professional than busy graphics while keeping costs manageable.
• Balance your size mix: While 2XL+ sizes cost more, most orders naturally include a range that averages out. If you're outfitting a group that skews larger, factor those upcharges into your budget planning.

Using Our Quote Calculator

Every product page includes a quote calculator that helps you estimate costs before diving deeper into customization. Scroll down on any polo product page and you'll find fields to input your quantity, decoration method, and number of colors. This tool gives you a ballpark figure for budgeting purposes, though it's limited to basic scenarios: single print locations, standard sizes, and no special effects.

For more accurate pricing, upload your graphics to our Design Studio on your chosen product. This lets you specify additional print areas, select your size breakdown, and see how special effects impact costs. You'll receive a detailed quote without any obligation to purchase, and you can save both your design and pricing for future reference.

Our sales team stands ready to help with special requests or questions via phone or chat—they're particularly valuable when you need multiple decoration methods, complex size distributions, or specialty services that go beyond standard options.

Making Smart Polo Decisions

Custom polo shirt pricing depends on multiple factors working together, from basic cotton shirts at $18 to premium performance polos reaching $80. Understanding how shirt type, brand selection, decoration methods, order quantities, and design complexity impact costs helps you make informed decisions that balance quality with budget. The biggest savings come from ordering in bulk, keeping designs simple, and planning ahead to avoid rush fees.

We've earned our position as a leader in custom apparel by delivering quality products, competitive pricing, and expert guidance when you need it. Whether you're outfitting a corporate team with embroidered logos or creating branded merchandise for your organization, we're ready to help make your project a reality.

Browse our full collection of polo shirts, use our quote calculators for initial budgeting, then jump into our Design Studio for accurate pricing tailored to your specific needs. Our sales team stands by to ensure you get the best quality and value for your investment—because great custom polo shirts shouldn't break the bank.