Custom band merch is often the first real money a band makes on the road, and it is also where a lot of bands lose money. The difference is planning: the right shirt, the right quantity, a smart size mix and a design that prints well. We print merch for musicians, cafés and small brands in Orlando and ship it worldwide, so here is the plan we wish every first-time customer had.
Start with who is buying
Before you pick colors, picture the person at your merch table. Are they at a sweaty club show in August, or a cold winter tour? Do your fans wear oversized tees or fitted ones? Answering this then tells you most of what to order.
- Warm shows and summer tours: lighter tees, maybe a tank.
- Cold tours and a loyal following: hoodies sell, even at a higher price.
- A streetwear-leaning audience: a heavyweight t-shirt feels worth the money.
How many shirts to order for a first run
Every band asks this, and the honest answer is: fewer than you think, but enough to make screen printing worth it. Screens cost the same for 24 shirts as for 200, so very small runs are expensive per piece. On the other hand, a closet full of unsold mediums is worse.
A practical way to size a first run of custom band merch:
- Estimate your crowds. First, add up the expected audience across the shows you have booked.
- Assume a small share buys. Only part of any crowd buys a shirt, so start conservative and treat the first shows as your test.
- Round to a screen-friendly number. 24, 48 and 72 are common breaks where the price per shirt drops.
- Reorder fast instead of overbuying. Keep the screens’ design files ready so a second run is quick.
Our minimum is 12 pieces per design. For a first tour, 48 to 72 shirts of one design is a common, sensible start.
Getting the size mix right
Size mix makes or breaks your profit. For example, order too many smalls and you will sell out of large on night two. So here is a starting split many merch sellers use for adult unisex tees. Adjust it if you know your crowd.
| Size | Share of the run | On 48 shirts |
|---|---|---|
| S | About 10% | 5 |
| M | About 25% | 12 |
| L | About 30% | 14 |
| XL | About 20% | 10 |
| 2XL and up | About 15% | 7 |
Still, this is a rule of thumb, not data from your fans. Track what sells at your first shows and adjust the reorder.
Design custom band merch that prints well
The best merch designs are bold, readable from across a room and limited to a few colors. For example, a two-color design on a black tee can look great and keeps costs down. Every extra color adds a screen and another pass on every shirt, as we explain in why fewer colors make better prints.
Also, think about placement. A big back print with tour dates is classic, but it is a second print location and a second setup. Instead, a strong front print alone sometimes sells better and costs less.
Get the artwork print-ready
Send vector files if you can, and outline your fonts. If your artist works in Photoshop, ask for full-size files at 300 dpi. Our artwork guide lists everything we need.
Pricing your merch
Work out your cost per shirt first, including shipping to you. Then price for the table, not the spreadsheet. Round numbers are easier to sell at a loud show, and a “tee plus sticker” bundle can move stock. For the cost side, see how much screen printing costs, or try the calculator on our home page.
Timeline: order earlier than you think
After all, a custom run needs a proof, approval, screens, printing and shipping. Most of our runs ship 7 to 10 working days after you approve the proof, and bigger runs can take longer. Add shipping time on top, especially if the shirts are going to a tour stop abroad. So start the process at least three to four weeks before the first show.
Shipping to the tour
We can also ship to your home, your venue or a hotel on the route. Tell us the date it must arrive, and we will say honestly whether we can make it. International shipping is tracked; customs times vary by country, as our shipping page explains.
Tees, hoodies or both?
The t-shirt is the classic merch item for a reason: it is affordable, everyone wears one and it travels well. Hoodies cost more to make, but they sell at a higher price and fans wear them for years. For a first run, many bands do a tee only. Once a tee sells well, adding a hoodie in the same design is a natural next step, and the artwork is already done.
Running the merch table
Good custom band merch can still sit unsold if nobody can see it. Hang one of each design where people can read it from a distance. Show the sizes you have left. Take cards, since many fans carry no cash. Finally, count what sells every night. That count is the data your next order should come from.
Selling custom band merch online
However, your merch table only reaches people at the show. An online store reaches everyone else. Keep a small stock of each size after the tour, or plan a second run timed with a release. Either way, the screens are the expensive part, and they are already paid for once the first run is done.
A checklist for your first custom band merch run
- One strong design, two or three colors.
- A blank that suits your crowd and season.
- 48 to 72 pieces with a sensible size split.
- Print-ready artwork and a clear placement.
- An order date three to four weeks before the first show.
Ready? Send your design through our custom run form with your dates and quantity. Then we will reply with a proof, a price and a ship date you can plan around.
Merch questions
How many shirts should a band order first?
Start conservative. For a first tour, 48 to 72 shirts of one design is a common, sensible start, and you can reorder quickly if they sell.
What sizes sell most?
In adult unisex runs, medium and large usually sell most. Track what sells at your first shows and adjust the reorder.
How far ahead should I order merch?
Start three to four weeks before your first show to allow for the proof, printing and shipping.
Can you ship merch to a tour stop?
Yes. We ship tracked to homes, venues or hotels, in the US and internationally. Tell us the arrival date when you order.
