DTF printing costs $1.05 to $1.95 per piece with no setup fees, staying flat from small to large orders. Screen printing costs $8 to $15 per shirt on small runs but drops to $0.60 to $1.20 per shirt at 500+ units due to $25 to $45 per-color setup fees. The crossover point falls between 75 and 150 units for simple designs.