Decoration Techniques / Embroidery
Embroidery for Custom Apparel
The most durable decoration there is: logos built with thread, stitch direction and backing. Properly digitized embroidery outlasts the garment itself — and signals premium from the first touch.
Overview
One Design. Several Layers.
Embroidery is priced and planned by stitches, not colours. These four factors decide the result and the cost.
Artwork
Simple, bold shapes embroider best. Fine lines under 1mm and small text under 5mm height need redesign or a print route.
Stitch Count
The real cost driver. A 5,000-stitch chest logo costs far less than a 30,000-stitch full back. We estimate stitch count from your artwork before quoting.
Surface
Stable knits, fleece, denim, canvas and caps embroider beautifully. Very thin or high-stretch fabrics need backing and design adjustments.
Result
Textured, premium, permanent. For flat photographic colour, choose digital or screen printing instead.
Suitability
Is This a Embroidery Job?
Almost every garment category can carry embroidery — with the right backing and digitizing.
T-Shirts & Polos
Left-chest logos are the classic. Lightweight tees need cut-away backing so the logo does not pucker the fabric.
Hoodies & Sweatshirts
Ideal surface. Fleece holds dense stitching well; 3D puff embroidery works best on structured sweatshirts and caps.
Jackets & Workwear
Denim, canvas and workwear jackets take large back embroidery. Seams and pockets are mapped before hooping.
Caps & Beanies
A core embroidery product. Structured caps suit 3D puff; beanies suit flat embroidery with stretch-aware digitizing.
How It Works
How Embroidery Behaves on Fabric
Stitches pull fabric. Digitizing compensates for that pull so the design keeps its shape on each specific fabric.
Flat Embroidery
Stitches lie directly on the fabric. Clean, detailed, works at small sizes — the default for logos.
3D Puff Embroidery
Foam is placed under the stitching, raising the design. Bold and tactile, but limited to simple shapes and thicker garments.
Appliqué
Fabric pieces are stitched onto the garment and edged with embroidery. Covers large areas at a fraction of the stitch count.
Materials
Choose Materials After the Fabric
Thread and backing are chosen against the garment, not from a catalogue page.
Polyester Thread
The standard: colourfast, strong, chlorine-resistant. Keeps colour through industrial washing.
Rayon Thread
Higher sheen for a dressier look. Slightly less durable than polyester under harsh wash conditions.
Backing
Cut-away for stretchy knits, tear-away for stable wovens, wash-away for delicate surfaces. Wrong backing is the main cause of puckering.
Process
From File to Finish
From artwork to stitched logo — the digitizing step is where quality is decided.
Review
Artwork is checked for embroidery feasibility: minimum line weight, text size, detail density.
Digitize
The design is converted to a stitch file — stitch type, direction, density and pull compensation set for your fabric.
Choose Thread
Thread colours are matched to your references. Physical thread cards beat screen colours.
Sew-Out
A test stitch-out on similar fabric checks the digitizing before garment sampling.
Hoop & Stitch
Garments are hooped with the correct backing and stitched in multi-head runs.
Finish
Backing is trimmed, loose threads are cleaned, and the logo is steamed flat.
Inspect
First-off approval, then in-line checks on stitch density, registration and thread trims.
Pricing
What Changes the Quote
Embroidery pricing is stitch-based. Three variables move the number.
Digitizing
A one-time setup per design. Simple logos are quick; complex crests take longer. Reorders skip this cost entirely.
Stitch Count
The per-piece driver. Roughly: every 1,000 stitches adds machine time. We quote stitch counts transparently.
Placements & Volume
Each additional placement is hooped and stitched separately. Unit price falls as quantity rises.
Quality Control
What a Failed Print Looks Like
We inspect against these known failure modes — agreed before production.
Puckering
Fabric gathers around the logo. Caused by wrong backing, excessive density or missing pull compensation — fixed at digitizing, not after bulk.
Gapping
Fabric shows between stitches that should touch. Density and underlay are corrected in the sew-out stage.
Thread Breaks
Broken threads leave gaps in the design. Tension and needle condition are checked per run.
Misregistration
Outlines drift from fill areas. Hooping stability and digitizing order are the controls.
Hoop Marks
Visible rings pressed into the fabric. Steaming and correct hooping pressure remove or prevent them.
Small Text Collapse
Letters under ~5mm fill in and become unreadable. Flagged at artwork review with a resize or redesign.
Sampling
Approve the Physical Result
A digital preview is not the approval standard. The sew-out is.
Digitizing Approval
You confirm the stitch preview: size, colours and placement on a mockup.
Sew-Out
A physical stitch-out on similar fabric checks density, coverage and thread colour.
Pre-Production Garment
The logo on the actual garment is your sign-off standard.
Bulk Checks
First-off approval, then in-line sampling against the locked sample.
Decision Boundary
Embroidery or Another Route?
Embroidery is not always the answer. Here is the honest boundary.
Embroidery
Thread-built logos, premium texture, permanent.
Best for: Chest logos, caps, workwear and premium branding
Screen Printing
Flat ink colour, sharper fine detail at large sizes.
Best for: Big graphic prints at quantity
Silicone & Rubber
Moulded 3D logos with a technical look.
Best for: Sportswear and outerwear branding
FAQ
Questions Before Sampling
What is the MOQ for custom embroidery?
From 50 pieces per design. Digitizing is a one-time setup, so reorders of the same logo have no setup cost and lower minimums.
Can you embroider photographs or gradients?
No — embroidery builds images from discrete stitches. Gradients can be simulated with thread blending, but photographic artwork belongs to digital printing. Send the artwork and we will tell you honestly which route fits.
What is the difference between flat and 3D puff embroidery?
Flat embroidery stitches directly onto the fabric and handles detail well. 3D puff stitches over foam to raise the design — bold and tactile, but limited to simple shapes on structured garments like caps and hoodies.
Will embroidery survive industrial washing?
Yes. Polyester thread is colourfast and chlorine-resistant, and the stitch itself cannot crack or peel like ink. The garment will usually wear out before the logo does.
How is embroidery priced?
One-time digitizing setup plus a per-piece price driven by stitch count and placements. A typical left-chest logo (5,000-8,000 stitches) at 100+ pieces usually adds $1.00-$2.50 per garment.
Send the Actual Job
Send what you have — artwork, a reference image or just an idea. The more of this list you include, the sharper our quote. We reply within 24 hours.
✓ Vector artwork (AI, EPS or PDF)
✓ Logo dimensions in cm
✓ Placement (left chest, back, sleeve, cap…)
✓ Garment style and fabric composition
✓ Thread colour references (Pantone or physical)
✓ Flat, 3D puff or appliqué preference
✓ Quantity per design
✓ Delivery country