Custom Embroidery

Our minimum is 12 pieces for embroidery. Below 12 the digitizing and thread-change setup don’t amortize well across the order — we’ll usually recommend a custom patch or DTF transfer for 1–11 piece runs. Quantity is the single biggest lever on per-unit price because the digitizing setup cost stays flat.

A typical left-chest logo (up to 10,000 stitches) on a Gildan polo at 24 pieces runs about $15–20 each including the polo. A cap front logo at 48 pieces is closer to $12–16 each. Larger back logos with 25,000+ stitches and 4+ thread colours can run $28–40 per jacket. Stitch count and thread colour count are the two main drivers — we’ll give you a stitch-count estimate before you commit.

Embroidery stitches thread directly into the garment — most premium feel, lasts the life of the shirt, but costs more and handles fine detail poorly. DTF (direct-to-film) heat-presses a printed transfer — unlimited colour, handles gradients and fine text, but looks like print not stitching. Woven patches are pre-made fabric patches sewn or ironed on — good for complex logos with fine detail, hats where embroidery isn’t possible, and a more casual look. We’ll recommend the right method for your logo and garment.

Close, but not exact. Embroidery thread brands like Madeira and Robison-Anton publish PMS-equivalent colour charts — we match to the closest available thread, which is usually within 1–2 Pantone steps of your brand PMS. True Pantone-exact isn’t achievable in thread. Send your PMS codes when you submit artwork and we’ll send thread-colour swatches for approval before stitching.

Standard production is 7–10 business days from artwork and digitizing approval. Digitizing adds 1–2 business days the first time we run a logo (one-time fee). Rush windows of 3–5 business days are available on most quantities for a rush fee. Hats, polos, and t-shirts run faster than heavy jackets, fleeces, and structured workwear.

Embroidery works best on bold, high-contrast designs with clean shapes — think logos that read clearly at 1 inch wide. Lines thinner than 1mm, text smaller than 5mm, tight gradients, and photorealistic detail will struggle in thread. If your logo has fine detail, we may recommend simplifying or switching to DTF. Send your vector file (AI, EPS, SVG) or a high-res PNG and we’ll let you know before digitizing.

On structured caps, embroidery area is typically 2.25″ tall × 4.5″ wide on the front panel, with smaller areas on side and back panels. Polos and t-shirts take a left chest up to 4″ × 4″, with full-front and back designs possible up to 10″ × 12″. Jackets and fleeces can handle full-back designs up to 12″ × 14″. Larger areas = higher stitch counts = higher cost per piece.

Yes. 3D puff embroidery (where a foam layer is stitched over to create a raised effect) is popular on cap fronts and works with bold, thick-lined designs. We also offer metallic threads, glow-in-the-dark thread, and appliqué (fabric cut-outs stitched onto garments for a large-scale look at lower stitch counts). Specialty effects add a small per-piece surcharge — we’ll note it on the quote.

Fine detail under about 5mm tall won’t read cleanly in thread — it tends to blob into indistinct stitching. Gradients can’t be stitched directly; they get converted to solid-colour steps which changes the look. If your logo has these issues, we’ll flag it before digitizing and offer three paths: simplify the logo for embroidery, switch to DTF or a woven patch for that specific placement, or proceed as-is with an honest preview of what it will look like stitched.

Yes — all embroidery requires a digitized file (a stitch-path file that tells the machine what to sew). First-time digitizing is a one-time fee, typically $35–75 depending on logo complexity and stitch count. Once digitized, the file is yours forever — reorders have zero setup cost. If you already have a digitized file (.dst, .emb, or .pxf) from another shop, send it and we’ll confirm compatibility.