Why Custom Branding Apparel Seems Expensive (and How Bulk Saves Money)

Understand “custom” costs, small vs. bulk runs, and how to save with Inkdnylon’s industry-leading embroidery pricing.

One of the most common first-time questions is: “Why does embroidery cost so much for just one item?” It’s fair—especially when you compare to retail brands like Ralph Lauren or Nike, where buying one polo feels normal. But those brands produce hundreds of thousands of garments in bulk, so their cost per piece is a fraction of a single custom job.

What “Custom” Really Means

  • Your logo must be digitized before stitching starts.
  • Machines are set up just for your art—even for one piece.
  • Threads, hoops, tension, and placements are calibrated per order.
  • Quality checks happen on your item, not a mass-run.

Whether you order 1 piece or 1,000, the setup work is nearly the same. That’s why the first item feels expensive.

Global reality: In manufacturing hubs like China, orders of 1–2 pieces are treated as “samples.” Samples cost more because they require the same expertise and setup without the volume to spread costs. Add in logistics—air shipping is costly, boats are slow—and there’s no real savings on small runs.

Industry-Leading Embroidery Pricing

Flat-Rate Model:

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

Details & specs: Contract Embroidery

Distributor Embroidery Pricing (ASI • SAGE • PPAI)

Inkdnylon also serves distributors and promo agencies with wholesale-level embroidery via ASI, SAGE, and PPAI. Pass savings to your clients without sacrificing quality. Learn more: Distributor Embroidery.

Decoration Methods We Offer

  • Embroidery — flat, 3D puff, appliqué, chenille, patches
  • Screen Printing — best for larger runs
  • DTF Transfers — vivid color for small or large runs
  • Vinyl — names, numbers, personalization
  • Rhinestones & Spangles — sparkle effect
  • Patches — embroidered, leather, PVC, chenille
  • Sublimation — full-color, edge-to-edge designs

Bottom Line

Custom = setup + expertise. One piece is a “sample” worldwide, so the per-item cost is naturally higher. Bulk orders spread those costs out—and that’s exactly how retail giants get low unit costs.

Good news: Inkdnylon’s $5 flat rate up to 5" (then $2.50 per additional inch) makes pro embroidery more accessible than ever. Combine that with distributor pricing for ASI, SAGE, and PPAI members to maximize savings.

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