When it comes to cost you have to use a lot of factors.

Garment cost and minimum order required

The average for a Beefy Tee (Hanes) is around 6 or 7 $ and as low as $3. Hanes and Gildan are the most common shirts and cost the least.

You can also go higher end with the American Apparel and Columbia catalogs.

A printers average order is around 12 shirts per design. Some upwards of 22.

[b]Design[b]

If you have an in-house designer this will be the cost of your designer.*

Printing companies will also design your shirts. An average cost would be $45 to $60 an hour for design plus 1 correction, alteration.

*If you are printing 4, 6 or 12 colors make sure your designer understands color separation.

Burning the Screen

If you use a temp screen the process will only be good for about 24 shirts before the emulation used wears away. The Average cost is around $15 for the screen

If you use a permanent screen the process has a few more steps but will last for a run of 1000+ shirts. The average is around $25 for this screen* but that also includes storage.

*The cost will go up some if you need a non stock mesh count for detailed lines 1point or smaller.

Labor

Most places include labor into the total costs of screening, burning and design but an average is $1 or $2 per shirt/hat/whatever


The initial setup, as with anything, is where you put out your money and only pay a garment and labor charge after that.

This is if you plan to use the screen and ink process.

The other options would be heat press or ink jet scanner directly onto the shirts (think café press)

Hope that helps some.