Paper Cuts & Post Shares: Why Paper Flyers Still Matter in 2025
February 5, 2025
Because No One Wants to Be Stuck with a Box of XS Tees That Didn’t Sell
Let’s be real—getting merch made can be expensive. You either drop close to a grand on a screenprint order or risk running out of the good sizes while being stuck with a pile of smalls no one wants. But what if you could print your own merch on demand, have endless options for different items, and still get that pro-level screenprinted quality—without breaking the bank?
Enter screen-printed heat transfers—a game changer for bands and DIY makers who want high-quality merch without high-volume orders.
What Are Screen-Printed Heat Transfers?
Think of these as screenprints you can apply whenever you need them. Instead of screenprinting directly onto a shirt, the design is printed onto a special heat transfer sheet using plastisol ink (the same stuff used in traditional screenprinting). The sheet is then pressed onto a garment using heat and pressure, permanently bonding the design to the fabric.
The best part? They look and feel exactly like standard screenprints—because they are screenprints. Just applied differently.
The Cost Breakdown: Heat Transfers vs. Traditional Screenprinting
Let’s compare the costs of ordering a standard screenprint batch vs. printing your own merch:
👕 Traditional Screenprinting (100 Shirts)
- Screen setup: $30 per screen x 2 (front and back) = $60
- Printing cost per shirt: ~$9
- Total for 100 shirts: $900
- Grand total: $960
Not bad, but if you’re a broke band pooling together cash from grandma’s birthday cards and selling socks on the internet, that’s a big upfront cost.
🔥 DIY Heat Transfer Setup
- Heat press: ~$200 (one-time investment)
- 100 heat transfer gangsheets: ~$250
- 100 blank tees: ~$400
- Total for 100 shirts: $850
That’s already cheaper than the screenprint order, but here’s where the real savings kick in:
- You now own a heat press, so your second merch run doesn’t have that extra $200 cost.
- You’re not locked into shirts only. The same transfers can be used on hoodies, hats, jackets, tote bags—whatever you want.
- You control inventory. Print only what you need, when you need it. No more boxes of unsold merch sitting in your closet.
How to Maximize a Gangsheets for Ultimate Merch Options
A 12x19” gangsheet is basically a canvas for all your designs. Instead of printing one design per sheet, you can pack multiple logos, graphics, and text into one.
What This Means for Your Merch:
✅ One design for shirts, another for hoodies, another for hats—all on one sheet
✅ Different colorways? No problem. Print multiple versions without ordering separate batches.
✅ One-off merch ideas? Easy. Need a sick custom jacket for your drummer? Done.
You don’t have to print everything at once, either. Keep your gangsheets stocked, and press merch as orders come in—or test new designs before committing to a big order.
What You Need to Get Started
The Pros & Cons of DIY Heat Transfer Merch
PROS:
✔ More flexibility – Print different sizes, colors, and garments without a huge upfront cost.
✔ On-demand printing – No more getting stuck with unsold merch. Print only what you need.
✔ Pro-level quality – Done right, you can’t tell the difference between a transfer and a traditional screenprint.
✔ Expand your merch lineup – Hats, hoodies, totes—you're no longer limited to just tees.
💀 CONS:
❌ Requires an upfront investment – But it pays for itself after your first batch of shirts.
❌ Takes some effort – You have to actually press the designs onto the garments yourself.
❌ Not the best for high-volume runs – If you’re selling 500+ shirts, a pro screenprinter is still the way to go.
FINAL THOUGHTS:
The Best of Both Worlds
Look, screenprinters are amazing—if you’re ordering in bulk, they’re 100% the way to go. But if you’re a smaller band, DIY brand, or just want more control over your merch, screen-printed heat transfers give you all the benefits of screenprinting without the massive upfront cost.
So don’t be afraid of the DIY route—invest in a press, get creative with your designs, and start making merch that fits your needs. Whether it’s a full run of tees or a single one-off hoodie, this method gives you more freedom, more options, and way less risk.
Got questions? Drop ‘em in the comments! And if you’re looking for live music in San Diego, you already know where to find us. 🤘
