I sat down and did some (heavily estimated) math.

I found a bulk dealer that sells the right kind of mesh in a few different colors. I know a professional costumer/seamstress who could conceivably do 10 jerseys in a hypothetical entirely custom order. Would is another question. I know where to look to find somebody to do custom embroidered patches. I'd have to ask around and leverage some connections. For a bit of background, I used to sell sewing machines, mainly embroidery machines and the classes on machine use and troubleshooting as well as the design software.

I managed to get it down to $220 ± $15 on materials and labor. Adidas seems to sell most of their jerseys at $230. There are a couple of limitations, mainly on chest patch size, since getting a non-industrial embroidery platform that does patches over 8"x8" is expensive. There are a few workarounds that I can think of, but I've never tried them. It's a process that would take some experimentation. The other big limit is bulk ordering materials. I guess ordering white and custom dyeing is an option, but...



Anyway, Spreadsheet.

List of Considerations and Assumptions:

• Overhead for any design quirks to make the patches bigger or any variations in material costs are not accounted for, mostly because it's hard to quantify time and resources that would be expended. The Design Billing pays off the licensure of the software and a couple of other things that I'd have to pay for to make this work.
  
• Embroidery in this format is pretty comparable to 3D printing. The hour count here is for a 10 letter name, 2-number patches, no front letters (As or C) and an 8x8 logo with a couple of thread changes, bobbin reloads and changes, and some extra tolerance.
  
• Jersey Assembly refers to pattern cutting, sewing, and finishing. I'm basing it on the Costumer's rate with practice. She Scares Me.
  
• I couldn't remember or find the datasheets I had on stitch length, stitches per inch, and stitch time. I know that I estimated generously, though. Better to be pleasantly surprised.
  
• Two hours later, I realized that I didn't account for sales tax. I fixed it, but gosh...
  
• The 2nd tab is where I got a little deep earlier and started going through to figure out how much overhead there'd be to stock colors of thread to do all of the teams.
  

Shit, now I've done most of the math. If there's enough interest, I'll see if I can get the ball rolling. It's probably a long shot, but I can ask.