How Much Does Custom Gym Clothing Cost in the UK?

Understanding Gym Clothing Costs

The cost of custom gym clothing breaks down into three components: the blank garment, the decoration (printing or embroidery), and the fulfilment (picking, packing and delivery). Understanding each component helps you price your merchandise profitably.

Garment Costs

| Garment | Entry-Level | Mid-Range | Premium | |---|---|---|---| | T-shirt | £3–£5 | £5–£8 | £8–£15 | | Hoodie | £12–£18 | £18–£25 | £25–£35 | | Sweatshirt | £10–£15 | £15–£22 | £22–£30 | | Cap | £4–£7 | £7–£10 | £10–£15 | | Leggings | £8–£12 | £12–£18 | £18–£25 |

Decoration Costs

• Screen printing — £2–£5 per print (volume dependent; cheaper per unit in bulk).
• DTF printing — £4–£8 per print (no setup cost, ideal for short runs).
• DTG printing — £4–£8 per print (best for full-colour one-offs).
• Embroidery — £3–£8 per position (premium finish for polos and fleeces).

Bulk vs Print-on-Demand: The Real Economics

Bulk Ordering

You pay the full cost upfront for a batch of garments. Per-unit cost is lower, but you hold stock and absorb any unsold inventory. A run of 50 hoodies at £20 each (garment + print) costs £1,000 upfront. If you retail at £40, your margin is £20 per hoodie — but only if every hoodie sells.

Print-on-Demand

You pay nothing upfront. Each item is produced only when ordered. Per-unit cost is higher (perhaps £22–£28 for a hoodie including print and fulfilment), but there is zero stock risk. If you retail at £40, your profit per hoodie is £12–£18. Over a year, with no dead stock, total profit often exceeds the bulk model.

Typical Retail Prices for Gym Merch

• Hoodies — £30–£45
• T-shirts — £18–£28
• Sweatshirts — £25–£38
• Caps — £15–£22
• Tote bags — £12–£18

Hidden Costs to Watch

• Setup fees — Some screen printers charge per-colour setup.
• Artwork fees — Complex design work may carry a charge.
• Delivery — Bulk orders may include delivery; print-on-demand usually charges per order.
• Storage — Holding stock requires space.
• Dead stock — Unsold sizes and designs are a direct loss in the bulk model.

How to Maximise Profit

1. Use print-on-demand to eliminate stock risk.
2. Price for perceived value — Premium garments command premium prices.
3. Offer a range — Multiple price points capture more members.
4. Refresh designs — New drops drive repeat purchases.
5. Bundle — Offer hoodie + tee bundles at a slight discount to increase average order value.

Next Steps

The most cost-effective way to start is a managed print-on-demand store — no upfront investment, profit from day one.