Custom Sportswear Logo Techniques: Screen Printing vs. Embroidery
Why Sportswear Brands Logo Decoration Matters?
A logo is not just a visual element—it conveys brand positioning, perceived quality, and functional durability. The right decoration technique ensures comfort, long-lasting wear, and differentiation in a competitive market. Screen printing and embroidery are the most common choices in sportswear manufacturing, but they differ significantly in material systems, process principles, fabric compatibility, and cost structures.
1. Process Principles and Material Systems
Screen Printing
Screen printing transfers ink through a mesh stencil onto the fabric surface, followed by flash drying and curing.
Ink Systems:
- Water-based: Soft, breathable, best for light-colored cotton or cotton blends.
- Plastisol: Rich color saturation and strong opacity, commonly used for dark bases and bulk runs.
- Silicone: High elasticity and crack resistance, ideal for polyester/spandex blends.
Key Process Parameters:
- Mesh count: 80–120 for large areas, 140–180 for fine detail.
- Squeegee hardness: 70–80A; higher angles create sharper edges.
- Curing: Must follow ink technical data sheets (TDS); dark polyester requires a blocker underbase to prevent dye migration.
Advantages: Vibrant colors, supports gradients, cost-efficient for bulk production.
Risks: Potential cracking on stretch fabrics; dye migration on dark polyester without proper blockers.
Embroidery
Embroidery creates raised logos by stitching threads directly into fabric.
Thread Options:
- Polyester: Highly durable, resistant to washing, sweat, and sunlight.
- Rayon: Softer sheen, but weaker against sweat and abrasion.
Key Process Parameters:
- Stitch types: Satin (for edges/small text), Tatami (for fills), Running (for outlines).
- Density: 0.35–0.45 mm; reduce density and add underlay for thin/stretch fabrics.
- Needle types: Ballpoint needles for knits, sharp needles for wovens.
- Stabilizers: Cut-away for durability, water-soluble topping for fleece/pile fabrics.
Advantages: Premium, textured, long-lasting, adds brand value.
Risks: Large areas may feel heavy and stiff; higher cost with increased stitch counts.
2. Fabric Compatibility and Risk Control
Different fabrics have varying tolerance to decoration methods. Common activewear fabrics such as polyester/spandex, nylon, cotton blends, and fleece each require specific process adjustments.
| Fabric Type | Screen Printing Suitability | Risks & Solutions | Embroidery Suitability | Risks & Solutions |
Polyester/Spandex | Anti-migration inks + blocker base; silicone for stretch fabrics | Dye migration, cracking → low-temp curing + blocker | Good for small logos | Reduce density + use stretch stabilizer |
| Nylon | Requires nylon adhesion promoter | Water-repellent finish → adhesion issues | Viable | Prone to skipped stitches; use sharp needles + strong stabilizer |
| Cotton/Blends | Water-based inks offer soft hand | Dark shades need extra opacity | Highly compatible | Large logos may feel stiff |
| Fleece/Brushed fabrics | Use high-solids ink, multiple passes | Ink sinking → flash curing between layers | Works with topping film | Stitches may sink → add underlay |
3. Cost and Lead Time Analysis
Screen Printing
- Cost drivers: Number of colors × screens, use of blockers, curing method.
- Pros: Highly efficient for bulk runs, low unit cost.
- Cons: Setup time and cost are higher for small orders or multi-color prints.
Embroidery
- Cost drivers: Stitch count (logo size × density), number of colors, stabilizer type.
- Pros: High value for small logos, outstanding durability.
- Cons: Large logos raise stitch count, cost, and lead time significantly.
Lead Time
- Screen Printing: Requires screen prep and color matching, ideal for large-scale runs.
- Embroidery: Requires digitizing but faster turnaround for multiple SKUs with small logos.
4. Typical Application Scenarios
Training T-shirts (Polyester/Spandex, frequent washing)
- Large graphics: Screen printing with anti-migration ink systems.
- Chest logos: Silicone printing or small embroidery.
Team Jerseys
- Numbers and large text: Screen printing.
- Team crests: Embroidery for texture and durability.
Outerwear, Hoodies, Jackets
- Embroidery adds premium quality and long-lasting branding.
- Alternative: Patches with heat-seal for lightweight flexibility.
Caps and Accessories
- Embroidery provides 3D recognition and stability on curved surfaces.
| Dimension | Screen Printing | Embroidery |
| Visual Effect | Vibrant, supports gradients | Raised, premium texture |
Durability | Depends on ink system | Extremely durable, wash-resistant |
Cost | Low per unit, best for bulk | Higher with stitch count |
| Hand Feel | Soft and adjustable | Localized stiffness |
| Best Applications | T-shirts, jerseys | Outerwear, caps, hoodies |
Screen printing and embroidery are not about which is better, but which matches fabric, usage scenario, and brand positioning. Screen printing is ideal for bulk efficiency and colorful designs, while embroidery excels at premium perception and long-lasting quality. A hybrid approach—using printing for base collections and embroidery for flagship or premium pieces—often delivers the best balance.
HUCAI specializes in premium activewear customization, offering screen printing, silicone printing, and embroidery solutions. Our intelligent production systems ensure 100% consistency from sample to bulk, compliant with international quality and sustainability standards.
👉 Contact us for samples and custom solutions.
Why is dye migration common on dark polyester?
Disperse dyes in polyester can migrate into ink layers at curing temperatures. Solutions include using a blocker base, low-temp curing, or migration-resistant inks.
Does embroidery make garments heavier?
Large embroidery logos can increase weight and stiffness. Solutions: reduce logo size, lower stitch density, or use patches.
Is embroidery suitable for high-stretch garments?
Yes, with reduced density and stretch stabilizers. However, silicone printing is often recommended for lightweight flexibility.
Can both techniques be used in one collection?
Absolutely. Screen printing for cost-effective base products, embroidery for premium or limited editions.
