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From single pieces to full crew runs, Merrill gets screen printed gear with honest pricing and a 5 to 7 day door-to-door timeline.
Merrill crews order screen printed gear from us because the numbers are public and the process is simple: free design help, a written proof within 24 hours, and delivery to any Merrill address in 5 to 7 business days.
Census numbers put Merrill at about 9,100 people on 7.5 square miles of Wisconsin, all of it covered by the same tracked shipping. The same run covers the neighboring communities too: Maine, WI (9 mi), Wausau, WI (15 mi), Rib Mountain, WI (18 mi) all order from the same shop at the same published pricing. The closest major installation is Fort McCoy, roughly 102 miles out, and unit orders from there run through this same process daily.
The whole process runs remote: rough idea in, free designer-built proof back, written approval, and finished gear delivered to Merrill.
Screen Printing demand around Merrill does not stop at the town line. Crews from Maine (9 miles out) order through the same process, which is why coverage is priced by pack, never by zip code.
When the count is high and the budget is fixed, light blanks and one-color prints deliver. A real designer, not an upload widget, checks every file before it goes near production.
Formation-wide runs are the bread and butter: single design, mixed sizes, pack rates that reward volume. What you approve in writing is what ships. That rule has no exceptions.
Crew tees built for daily abuse: heavy blanks, cured ink, and reorders that match exactly. Start from a napkin sketch if that is what you have. Turning rough into print ready is the job.
Event shirts priced before the first form is printed, so selling at a profit is arithmetic, not hope. One point of contact owns your order from first proof to delivery confirmation.
One run covers the team and the bleachers: kid sizes and adult sizes priced together. Rush timelines get quoted honestly. If we cannot hit the date, we say so before you pay a cent.
Reunion gear that gets the year right, drawn in-house and printed for every generation at once. Start from a napkin sketch if that is what you have. Turning rough into print ready is the job.
This shop exists for the military community, and it shows in how orders run. Deadlines are treated like formation times, proofs are honest instead of optimistic, and when Merrill customers call, a person who owns the order answers.
It also means we say no when we should. If a design will not print well at the size you want, or a date cannot be hit, you hear it before you spend money, not after.
Upload art or add text in the Design Lab, set sizes and quantities, and the full estimate, shipping included, is on screen before you give anyone your email.
The right blank depends on budget, season, and how hard the gear will be worn. For Merrill customers, these three earn their keep.
Big-run economics start here: light ringspun cotton from $12 at volume, with the front print already in the price. Reorders match the first run exactly because we keep your art and specs on file.
Eighty-plus colors of 5.3oz heavy cotton, from military green to every heather, that keeps its shape through the laundry years. Ask for the honest option and you get it, even when it is the cheaper one.
An 8.0oz fleece crew with a clean uninterrupted front, the best canvas we stock for big crests and old school block lettering. The proof comes first and it is free, so what arrives is exactly what you signed off on.
Design help is not an upsell here, it is how orders start. Describe the concept in a sentence, attach whatever reference you have, and within 24 hours a real designer returns a proof drawn as clean vectors, era-correct where it matters. Revisions cost nothing and continue until the proof is right, and your written approval is the only thing that sends it to production.
The Design Lab is there when you want to drive: upload, place, and price the design yourself on the exact garment we print.
Start the budget from the real numbers: published light cotton tee packs, front print built into every figure Merrill customers see.
| Pieces | Total | Each | Ship | Back print add |
|---|---|---|---|---|
| 10 pack | $180 | $18 ea | $18 | $4 ea |
| 15 pack | $250 | $16.67 ea | $18 | $4 ea |
| 20 pack | $320 | $16 ea | $20.99 | $4 ea |
| 25 pack | $375 | $15 ea | $20.99 | $3 ea |
| 50 pack | $700 | $14 ea | $22.99 | $2 ea |
| 100 pack | $1200 | $12 ea | FREE | $2 ea |
Options price per piece: back prints at the listed rate (falling to $3 at 25 and $2 at 50), oversized full-body fronts at $3 under 25 pieces or $2 above, and 2XL-plus sizes at $6 under 25 pieces or $4 above. Every heavier garment keeps this same pack shape at its own numbers, and the Design Lab totals it live while you build.
Send the idea through the quote form or build it yourself in the Design Lab. A napkin sketch photographed on a phone counts, our designers have built full unit runs from less.
The proof arrives inside a day, drawn at print size on your chosen garment and color. Change anything, as often as needed, at no cost.
Nothing goes to press until you approve the proof in writing. What you sign off on is exactly what prints, that is the whole point of the proof.
Five to seven business days covers printing and delivery. Tight timeline? Rush gets a truthful quote, not a hopeful one.
Art, thread colors, and size history stay archived, so the next season run starts with one email.
Delivery to Merrill addresses follows one simple clock: 5 to 7 business days including production, with tracking from the moment it leaves. Hit 100 pieces and the shipping line drops to zero.
Every box leaves counted, tracked, and matched to your roster. Shortages and shipping damage are on us to fix, fast, because delivery day is the only day the customer remembers.
Order ten, order fifty, order five hundred: 10 pieces is our floor, and for your Merrill crew, bigger packs simply pull the per-piece price down.
File quality is our problem, not yours: vectors are ideal, 300 DPI PNGs work, and weak files get redrawn at no charge.
Yes. We ship to all 50 states and to APO and FPO addresses for deployed and overseas service members.
That is the point of the Design Lab: the complete number, packs, back prints, size upcharges, shipping, updates live while you design, before any contact form.
Standard production plus shipping takes 5 to 7 business days. Rush options are available on many orders, tell us your date and we answer honestly.
Always, at no charge. A designer takes your rough input, redraws it print ready, and has a proof in your inbox inside a day, with unlimited revisions after.
More answers on the full FAQ page.
The Merrill coverage page shows the full picture, screen printing statewide zooms out, and the service page covers the method itself. Other services in Merrill: Embroidery, DTG and DTF Printing, Sublimation, Banners and Signs, Custom Design.
Send the idea, get a free proof in 24 hours, approve it in writing, and pay exactly the published pack price.