Embroidery FAQ — Custom Embroidery Questions Answered
Embroidery FAQ — Custom Embroidery Questions Answered
Embroidery is the process of stitching a design directly into fabric using thread. It produces a dimensional, premium look that is associated with professional and high-quality apparel. Here’s what you need to know before ordering embroidered items.
Main Street Shirt Company offers commercial embroidery in-house in Illinois on caps, polos, jackets, bags, and other soft goods.
The Basics
What is embroidery?
Embroidery is a decoration method where designs are stitched directly into fabric using thread. A digitized embroidery file tells the machine exactly how to stitch each element of the design — stitch type, direction, sequence, and density. The result is a raised, three-dimensional design that is part of the garment rather than applied on top of it.
What is the difference between embroidery and screen printing?
Screen printing applies ink to the surface of a garment. Embroidery stitches thread into the fabric. The practical differences are: embroidery is thicker and more textured, better suited for structured items like caps and polos, and is associated with a professional or premium look. Screen printing is thinner, more vibrant in color, and better suited for t-shirts and hoodies with complex or large artwork. Neither is universally better — they serve different applications. See the Screen Printing FAQ for comparison.
What is the difference between embroidery and DTF?
DTF applies a heat transfer to the surface of the fabric. Embroidery stitches thread into the fabric. DTF handles full-color photographic artwork at any size. Embroidery handles simpler designs in thread colors on items that can’t easily be heat-pressed (like structured caps). For business logos on polos or hats, embroidery is often the preferred method because it looks more professional. For large, detailed, or multi-color designs on t-shirts, DTF is more practical. See our Embroidery vs. DTF comparison.
What Can Be Embroidered?
What items can be embroidered?
Common embroidery items include:
- Baseball caps and structured hats
- Polo shirts and button-downs
- Jackets, vests, and outerwear
- Beanies and knit caps
- Tote bags and backpacks
- Staff and workwear shirts
- Golf shirts and performance polos
Can you embroider t-shirts?
Yes, but with limitations. T-shirts have a lightweight, stretchy knit fabric that can pucker or distort with heavy embroidery. Embroidery on t-shirts works best for small, simple left-chest logo designs. Large, complex designs on t-shirts are generally better executed with screen printing or DTF. Ask us for guidance on whether embroidery makes sense for your specific t-shirt project.
Can you embroider hats?
Yes. Embroidery is the standard and preferred decoration method for structured caps and beanies. Screen printing and most heat transfer methods do not work well on structured caps because the curved and rigid surface prevents proper contact. Embroidery machines are designed to hold structured caps in place during stitching.
Artwork and Digitizing
What is embroidery digitizing?
Digitizing is the process of converting artwork into an embroidery file (typically .DST or .EMB format) that tells the embroidery machine how to stitch the design. Not all artwork translates directly — thin lines, small text, and photographic detail often need to be simplified for embroidery. Digitizing is done by a human operator with embroidery-specific software, not automated.
Does my file need to be digitized before embroidery?
Yes. Every embroidery job requires a digitized stitch file. If you don’t have one, we will digitize your artwork as part of the order process. Digitizing fees vary based on design complexity. Simple one-color logos are less expensive to digitize than complex multi-color designs.
What artwork file should I send for embroidery?
Vector files (AI, EPS, SVG) or high-resolution PNG files work well as source artwork for digitizing. The cleaner and simpler the artwork, the better it will translate to embroidery. Highly detailed illustrations, thin lines, and small text are difficult to execute well in embroidery and may need to be simplified.
Can embroidery reproduce photographs or gradients?
Not practically. Embroidery uses solid thread colors and stitch patterns. Gradients, photographs, and complex color transitions do not translate to embroidery in the way they do with printing. For photographic or full-color designs, DTF printing is the appropriate method.
Thread Colors and Design Limitations
How many thread colors can an embroidered design have?
Most commercial embroidery machines support multiple thread colors per design. Practical limits depend on machine configuration. Designs with 8 or fewer thread colors are standard. Beyond that, complexity increases. Because embroidery cannot reproduce gradients or full-color photos, the design should be simplified to solid areas of color for the best result.
Can you match my exact brand color in embroidery thread?
Thread colors are selected from available thread inventory, which covers hundreds of colors. Exact Pantone matching is not always possible — embroidery thread color matching is an approximation rather than a precise match. We will select the closest available thread to your specified color. For exact color-critical applications, ask us before ordering.
What is the minimum embroidery design size?
Very small text (under approximately 4mm tall) is difficult to stitch cleanly because the needle and thread have physical limits to the detail they can produce. Thin lines, small lettering, and fine details may need to be thickened or simplified for embroidery. We will flag these issues during the digitizing process.
Pricing and Minimums
How is embroidery priced?
Embroidery is primarily priced by stitch count — the total number of stitches in the design. More stitches = longer machine time = higher price. A simple left-chest logo (5,000–10,000 stitches) costs less than a large, detailed back design (50,000+ stitches). Pricing also includes a one-time digitizing fee for new designs. Contact us for a quote.
Is there a minimum order for embroidery?
We work with customers from single-piece orders up to large runs. The economics of embroidery are different from screen printing — there is no screen setup, so small quantities are more practical. However, the digitizing fee is a one-time cost that is more efficient when spread across larger quantities.
Care and Durability
How durable is embroidery?
Embroidery is extremely durable. Thread stitched into fabric will not fade, peel, or crack the way surface prints can. With normal garment care, an embroidered logo will outlast the garment itself. This is why embroidery is the standard for professional workwear, uniforms, and premium branded apparel.
Can embroidered items be washed normally?
Yes. Embroidered items can be machine washed and dried under normal conditions. Turning garments inside out before washing is a good practice to reduce friction on the embroidery. Avoid bleach, which can affect thread color.
Ready to embroider? Contact Main Street Shirt Company at info@mainstreetshirtcompany.com with your artwork and we’ll guide you through the process.