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@Velocio
I haven't reduced it to an exact science. It depends on the number of colours, whether it prints to the edge, etc. But each design needs to cover the cost (with profit) of making the screens to do the print... after that there are normal per-unit costs (shirt + ink + printing + distribution).
But the key point: Each shirt has to cover the production of the screens it requires.
We may make loads of designs, but I can say with surety that if there is a demand for 50+ shirts of a design, then it gets made.