Production volume thresholds and material cost curves
The relationship between volume and unit cost follows a non-linear curve that depends on three variables: print method setup, material cost, and packaging setup. For apparel (cotton polos with silk-screen logo), the curve looks like: 100 units at PLN 22–28 per unit, 500 units at PLN 12–18, 1,000 units at PLN 9–13, 5,000 units at PLN 5–8, 10,000 units at PLN 4–6. The breakpoint where material cost dominates over setup cost is around 500–1,000 units. Below that, you pay for setup; above that, you pay for material and labour.
For hard goods (ceramic mugs with sublimation print), the curve is similar: 100 units at PLN 8–14 per unit, 500 units at PLN 5–8, 1,000 units at PLN 4–6, 5,000 units at PLN 3–4, 10,000 units at PLN 2.5–3.5. Hard goods have a higher material cost component relative to setup, so the curve flattens earlier than apparel.
For premium kits (leather portfolio, premium pen, presentation case), the curve is steeper because the components have less volume elasticity: 100 units at PLN 280–420 per kit, 500 units at PLN 220–320, 1,000 units at PLN 180–250, 5,000 units at PLN 150–200. Premium kits are dominated by component cost, not setup cost, so volume savings are smaller in percentage terms.