The good news is you can do small batch printing without drowning in boxes of leftovers. You just need to know what to ask for, and how to pick the right products and print methods for low minimum printing.
Why printers push big minimums
Most big online printers are built around volume. They set up their machines to run hundreds of the same thing at once, which only makes sense if you're ordering large batches. The setup takes time, the clean-down takes time, and they'd rather do one job of 200 than ten jobs of 20.
That's why you'll often see high minimums and low prices per unit. It works if you're a large business or running a big event. It doesn't work if you're a local café, club, side hustle or small team that just wants a small merch order that doesn't eat your whole budget or fill your storage cupboard.
The trick is finding print options where the setup is lighter, the process is more flexible, and the minimums can come down.
Best options for printing just a few items
Not all printing methods are equal when it comes to printing a few items. Some are made for big runs, others are perfect for testing ideas or stocking a small shelf.
For apparel printing, digital printing or direct-to-film (DTF) transfers work well for smaller quantities. They let you do full-colour designs on a handful of shirts or hoodies without needing to hit huge minimums. Screen printing is still great, but it makes more sense once you're doing larger runs, because the setup is more involved. Our guide to DTF printing explains the difference.
Rule of thumb: for a handful of shirts, or a design with lots of colours, go digital or DTF. Once the run is big and the design uses only a few flat colours, screen printing starts to make sense.
For promotional items like mugs, bottles and other hard goods, some products suit short runs far better than others. Items like ceramic mugs, stubby holders and tote bags can often be done in low quantities. You may pay a bit more per item, but you're not stuck with 200 units you can't shift.
If you're not sure which method suits your idea, start by telling us what you want to print, how many you realistically need, and when you need them by. We'll match it to the process and production partner that make sense for where you're at.
How many should you actually order?
When you're starting out, it's easy to either over-order out of optimism or under-order out of fear. A better way is to think in stages.
For a new design or idea, use small batch printing as a test. Order just enough to:
Cover your team or regulars
Have a few extras to sell or give away
See how people respond in the real world
If it sells or gets good feedback, you can reorder with more confidence. If it doesn't, you haven't tied up a pile of cash in boxes of merch that never moved.
For internal use - staff shirts, branded aprons, club gear - you can start with a small merch order as well. Once you know sizes, fit and comfort are right, you can roll it out wider without any nasty surprises.
Before you order: get a couple of people to try on the garment in a few sizes first. Sizing varies between brands, and it's much easier to fix on a small first batch than on the whole team's order.
Ways to keep small runs affordable
Short runs will nearly always cost a bit more per piece than big ones. The trick is to keep the total spend sensible.
A few ways to do that:
Simplify your design. One strong graphic in one position costs less than a full front, back and sleeve print.
Choose the right products. You don't need the fanciest garment for a first run. Pick something solid and comfortable that won't blow the budget.
Think in tiers. Start with a small first batch. If it works, your second order can be bigger, and larger runs bring the cost per piece down.
Being upfront about your budget also helps. Get in touch with your rough spend and your ideal quantity, and we'll show you what's realistic without upselling you into boxes you don't need.
When a small batch is the smart move
Ordering fewer items isn't just about saving money. Sometimes it's the smartest move for your brand.
Small runs are perfect when:
You're testing a new logo or design and don't want to commit big yet
You're running a one-off event and don't need leftovers
You're a small business with limited storage space
You want limited edition merch to feel special and scarce
Low minimum printing keeps you flexible. You can learn what your customers actually like, adjust your designs, and grow your range over time instead of guessing from day one.
Ready to try a small merch run?
If you've been putting off merch because you thought you had to order hundreds, you don't. You just need the right setup and someone who's happy to work with smaller quantities.
Bring us your idea - rough sketch, finished file, or even just "I want shirts for my team but not a mountain of them." We work with everyone from schools and clubs to small businesses on merch in manageable quantities. We'll help you choose good products, pick a print method that suits small runs, and work out numbers that make sense for your budget.
No pressure to go big, no judgement if you're starting tiny. Bendigo businesses, clubs and side projects can get quality merch without having to fill a garage to do it.
Start with a tee: our classic tee is priced live on the product page - choose your colour, sizes and quantity, upload your design or have us design it.
