Embroidered Shirts: What Can and Can't Be Stitched Well
By The Velocity Wear Team
Embroidered shirts get nearly two thousand UK searches a month with almost no competition. People want the look: stitched, textured, premium. What they don't always know is that embroidery has limits. Knowing them upfront saves a disappointing proof.
Garments that embroider beautifully
- Polo shirts, especially piqué. The texture hides the backing and holds stitches neatly.
- Sweatshirts and hoodies, which are thick enough to carry denser designs.
- Heavier t-shirts, around 200 GSM and up, with small designs.
- Caps and beanies, which are made for it.
- Jackets, softshells and fleeces.
- Towels, where a stitched logo or monogram looks luxurious.
Garments that need care
- Lightweight t-shirts, which can pucker around stitching.
- Very stretchy fabrics, where embroidery can distort.
- Thin performance fabrics, which need the right backing and a lighter design.
- Waterproof garments, where stitching can compromise waterproofing.
Design sizes that work
- Left chest logos: about 7 to 10 cm wide.
- Sleeve logos: about 5 to 8 cm wide.
- Cap fronts: about 10 to 12 cm wide, up to about 5 cm tall.
- Centre chest on sweatshirts: up to about 20 to 25 cm wide.
What doesn't stitch well
- Text under about 5 mm tall.
- Hairline strokes and very thin outlines.
- Gradients, shading and photographic images.
- Lots of small separated shapes, which leave messy connecting threads.
Digitising, explained
Before a machine can stitch your logo, the artwork is converted into a stitch file that controls direction, density and the order of stitching. This process is called digitising. It's the difference between crisp lettering and lumpy lettering, even with the same logo. Always review the digital proof closely.
Thread colour
Thread comes in a large but fixed range of shades. Give a Pantone reference and we'll pick the nearest match. Metallic threads add shine but work best for small accents.
Preparing artwork
Send a vector file if you have it: AI, EPS, SVG or PDF. A high-resolution PNG works too. If your logo has a tagline or small details, consider supplying a simplified version for embroidery.
Caring for embroidered garments
Embroidery is durable, but a few habits help it look new for longer. Wash inside out. Avoid very hot washes that can shrink the fabric around the stitching. Don't iron directly on the embroidery; iron on the reverse or use a cloth. And avoid tumble drying on high heat, which can make some fabrics pucker around the design.
Budgeting for embroidery
Embroidery cost depends mostly on stitch count, which rises with size and fill. A small outline logo is cheaper than a large solid badge. If budget matters, reduce solid fill areas or scale the logo slightly. On our calculator, embroidery adds a modest amount per piece for a standard logo.
Names, initials and small personalisation
Names and initials are some of the most popular embroidery requests. Keep letters at least about 5 mm tall in a clean font, avoid very long names at small sizes, and check spelling carefully on the proof. For groups, supply one list with each name exactly as it should appear.
Patches as an alternative
For very detailed badges, some brands use an embroidered or woven patch sewn onto the garment. Patches can hold finer detail and add a heritage look. Ask whether a patch suits your design.
When to print instead
Large designs, photos and many-colour artwork are better printed. Plenty of garments combine both: stitched chest logo, printed back. See printed vs embroidered t-shirts.
Ready to order? See polo shirts, custom hoodies or caps. Minimum 20 per design, sizes mixed, 10 to 15 working days after artwork approval.
