One of the most common questions we get from Canadian businesses is some version of: “How much does it actually cost to manufacture custom hoodies?” It’s a fair question, and the honest answer is that it depends on a lot of variables — but we can give you real numbers to work with.
This breakdown covers what goes into the cost of a custom hoodie from a B2B manufacturing perspective, and what you can expect to pay at different order volumes in 2026.
The Main Cost Components
Before you see a per-unit price, understand what goes into it:
Fabric
Fleece quality varies dramatically. A basic 260 GSM cotton-polyester fleece is the standard mid-market weight — comfortable, affordable, holds decoration well. Premium 320–400 GSM fleece costs more but gives you that substantial feel that customers associate with quality. For a standard pullover hoodie, fabric alone typically accounts for 40–55% of the manufacturing cost.
Cut and Sew
The labour involved in cutting pattern pieces and assembling the garment. This varies by factory location. Bangladesh and Vietnam-based factories — which produce the majority of the world’s hoodies — range from $3–7 USD in cut-and-sew cost per unit depending on complexity and order volume.
Decoration
Screen printing a single-colour logo on a hoodie chest adds roughly $1.50–3.50 per unit at standard volumes. Embroidery on a left chest logo runs $2–5 per unit. Full-chest oversized prints cost more. Puff printing (3D raised ink) is a premium option.
Labels, Hang Tags, and Packaging
Often forgotten in early cost estimates. Custom woven neck labels, tear-away labels, care labels, branded hang tags, and polybag packaging can add $1–3 per unit to a premium product.
Shipping and Import
For orders shipped from Asia to Canada, freight (sea) typically works out to $1–2.50 per unit depending on volume. Air freight is significantly more expensive and only makes sense for rush orders. Import duties on finished apparel to Canada are around 18% of the declared value.
What Does This Add Up To?
Here’s a realistic range for a standard custom pullover hoodie (300 GSM fleece, 80/20 cotton-poly, screen print or embroidery decoration, basic packaging):
| Order Quantity | Approx. Cost Per Unit (CAD) | What This Includes |
|---|---|---|
| 100–200 units | $28–38 | Manufacturing + standard decoration + sea freight |
| 300–500 units | $22–30 | Manufacturing + standard decoration + sea freight |
| 500–1,000 units | $18–24 | Manufacturing + standard decoration + sea freight |
| 1,000+ units | $14–20 | Manufacturing + standard decoration + sea freight |
These are landed costs — what you pay to have the product arrive at your door in Canada. Add your margin and you have your retail or wholesale price.
Why Are Retail Hoodies So Much More Expensive?
A branded hoodie at a retail store for $90 isn’t coming from a $90 manufacturing cost. The typical retail markup on apparel is 3–5x the wholesale cost, and wholesale is already marked up from manufacturing. A $90 retail hoodie probably costs the brand $25–35 to produce and $45–55 wholesale before it hits the store.
This is why custom manufacturing makes economic sense for businesses buying at volume — you’re cutting out most of that chain and paying closer to actual production cost.
Canada vs. Overseas: Honest Comparison
There are some apparel manufacturers in Canada who do cut-and-sew domestically. The cost difference is significant — Canadian labour costs mean domestic manufacturing typically runs $45–90+ per hoodie depending on complexity, before decoration. For most volume buyers, this only makes sense for very small, high-margin runs where “Made in Canada” is a genuine selling point that justifies the premium.
For most Canadian businesses — sports teams, corporate gifting programs, retail brands, construction companies ordering workwear — overseas manufacturing managed by a Canadian company is the practical reality. The key is working with a partner who has established factory relationships, enforces quality standards, and can give you realistic lead times.
Hidden Costs New Buyers Often Miss
- Setup/screen fees: Most manufacturers charge $35–75 per screen colour for initial setup. This is a one-time cost per design.
- Sampling: Pre-production samples (which you should always request) typically cost $80–200 per style.
- Size breakdowns: More sizes in your order means more complexity. A 6-size run (XS–3XL) is more complex to manage than just S/M/L/XL.
- Duties and brokerage fees: If you’re importing yourself, you’ll need a customs broker. Budget $150–300 per shipment for brokerage.
Getting an Accurate Quote
The only way to get a real number for your specific project is to talk to a manufacturer with your actual specs — fabric preference, style, decoration detail, quantity, and timeline. General estimates like the ones above are a useful starting point, but they’re not a quote.
We work with Canadian businesses of all sizes on custom hoodie manufacturing — from 150-unit corporate orders to 2,000+ unit bulk runs. Send us your project details and we’ll get back to you with a detailed cost breakdown, usually within 24 hours.