Using embroidery on T-shirts and other clothing

Embroidery services for clothing have been going for over twenty-five years. Before automatic machines became cost-effective, all commercial embroidery had to be done by hand. Then, Computer Numerical Control (CNC) machines were developed. This led to very basic, single-color designs to be possible. Now multi-coloured detailed logos can be embroidered quickly and efficiently.

How does embroidery compare with printing for various items of clothing? We have had a look at the issues:

Embroidery compared with printing - One of the key differences in the way that embroidery services operate relative to printing services is costings. If you get your logo printed using silkscreen printing, for example, you will pay more for every colour you use. This is because every colour requires a separate plate and another stage in the process. With embroidery, the costs work on the number of stitches so the size and density of stitching are important factors to consider.

With silkscreen printing, large, simple and bold designs work well. Embroidery tends to be more for premium items that get a lot of use and get washed regularly. Workwear is a good example, or school uniforms and sports club jumpers.

Embroidery issues - The embroidery process produces a premium quality finish. Unfortunately, it can go wrong. Here are some potential pitfalls to be aware of:

Inconsistent thread density - On the computer screen, it may look fine. On the garment, it may look like a threadbare carpet! The successful transfer of the logo image into the CNC program that the embroidery machine reads is critical. The person setting up the run needs to understand both the machine and the software in use. If they don't then there may be missing stitches on the garment. There is also the risk that too many stitches means that you end up paying too much.

Puckering - I have personal experience of this on company polo shirts! Too much tension in the embroidered material and the logo will pull the cloth in. This is especially true after washing. This is sometimes caused by a high density of stitching in the logo itself and sometimes by the stretching of the base material. Either way, your premium product soon looks awful.

Placement issues - The way that the garment is set up can affect the logo position. Operator error can cause inconsistencies in position and alignment.

Color matching - Batches of thread from different suppliers can vary. You should always get a sample produced by whoever supplies you with embroidery services. Sometimes the exact Pantone color is important to your corporate identity. If that is the case then check the color against existing silkscreen printing materials for example.

Digitisation of small details - Small details on the logo pattern or text (think school mottos) may look OK on the computer screen but the reality can be very different. A change of font can work but it may be necessary to change the design to suit the embroidery.

Conclusion - using embroidery on T-shirts and other clothing - Embroidery services companies will be able to advise you on your exact requirements for logos on clothing. They certainly give a more premium look than 'say' silkscreen printing, but they do have some issues.

It does not matter how rushed you are, you should always get a sample stitched on one of your garments to check for the issues raised above. Your company, club or school's brand is at stake. Do not risk damaging it!