Embroidery vs Screen Printing Explained

One of the most common subjects we get asked about at Positive Branding is the pros and cons of embroidery vs screen printing. Embroidered garments are important for their premium appearance and suitability for professional settings, while screen-printed garments are ideal for casual settings and specific uses due to their affordability and design options. In this article, we aim to explore everything you need to know so that you can make the best choice when ordering your corporate workwear.

What is embroidery and embroidery machines?

This refers to a needlework technique for decorating garments. Many of us will remember learning in school how to use a needle and thread to create patterns and words on fabric. Today, workwear suppliers use state-of-the-art embroidery machines that harness digital technology to recreate logos, names, and other designs on uniforms and other professional apparel.

The process starts with the creation of a digital file of the artwork that can be read by the embroidery machine. Next, the most suitable type of thread and embroidery technique is chosen based on the colour of the artwork and the garment material. Selecting the right embroidery threads is crucial for matching colours and ensuring the custom designs are visually appealing and aligned with the client’s vision.

The garments are then prepared with frames, also known as hoops, to hold the material securely while the embroidery machine precisely stitches the design. The three main techniques are a running stitch for outlines and fine details, a satin stitch for a smooth, glossy finish, and a fill stitch for covering large areas with colour.

What is the screen printing process?

The term screen printing describes the method of applying artwork and text onto garments using a stencil (known as a screen) and ink. This cost-effective technique can produce high-quality, vibrant and durable results. A mesh screen plays a crucial role in transferring ink onto various fabrics, serving as a stencil that allows for detailed designs to be printed.

Using ink allows printers to produce a wide range of bold colours for maximum impact. Modern inks, such as plastisol and water-based ink, bind with the fabric for longer-lasting results that can withstand wear and tear, as well as frequent machine washing.

Before printing can start, the digital file of the design needs to be converted into individual screens for each colour. Screens are made from a mesh material that is coated with a light-sensitive emulsion – the stencil is created when the screen is exposed to light with the design overlayed. Ink is then pressed through the screen onto the garment using a squeegee. This process is repeated for each colour. Heating dries the ink, ensuring it attaches to the fabric. The screen printing process has historical origins tracing back to the Song Dynasty, highlighting its relevance in choosing customization methods for apparel.

Screen printing inks

Choosing the right ink is crucial when choosing screen printing for your branded clothing and merchandise as each type will make a difference to the finished product. Inks consist of three basic components: liquid, colour and the bonding agent (also known as substrate).

Regarded as the best choice for t-shirts, plastisol ink is versatile and, as the name suggests, is plastic-based. When applied, the ink sits on the surface of the fabric rather than soaking in. The combination of affordability and reliable results has made plastisol the industry standard ink for screen printing. Furthermore, the ink cures quickly, requiring less time and effort to dry.

Here are the main benefits of plastisol ink:

  • Vibrant colours
  • Produces fine details
  • Long-lasting finish
  • Durable for washing
  • Suitable for a variety of fabrics.

Favoured for its environmental benefits, water-based ink is generally not as reliable or versatile as plastisol. The finished design can appear less vibrant, and matching colours is generally not as reliable. While the water content makes the ink kinder to the environment, the curing process takes longer and uses more energy. The ink’s shelf life is also much shorter than plastic-based inks. However, water-based ink is popular due to the following attributes:

  • Seen as an eco-friendly choice
  • Produces softer prints
  • Feels lighter to wear as ink is absorbed by the fabric
  • Good level of detail.

 

The third choice is discharge ink, a process that reduces the original dye in the fabric and replaces it with ink. While the end result can fade quicker than other inks, this can be a positive when trying to achieve a vintage look. This method has a range of benefits:

  • Softer prints
  • Great on cotton.
  • Retro effect for t-shirt designs
  • Good level of print detail.

 

Embroidery vs screen printing: key differences 

To make an informed choice between embroidery vs screen printing, you need to understand the following differences:

An embroidered logo offers a professional and elegant appearance, making it a preferred choice for companies seeking a premium presentation of their logos. Embroidered logos are sewn into the fabric, making them less prone to fading or damage compared to printed patterns while also offering a three-dimensional appearance that enhances the overall aesthetic of the clothing.

4.1 Placement and Appearance

The placement of a logo embroidered on garments is typically on the left chest or sleeve of polo shirts, hats, and jackets. This placement not only enhances the professional look but also ensures the logo is prominently displayed.

4.2 Durability

Embroidery is known for its durability. The threads used in embroidered logos are less likely to fade or wear out over time, unlike screen-printed items, which may crack or peel after multiple washes.

4.3 Cost

While embroidery can be more expensive than screen printing, it offers a higher-quality finish. However, the cost can vary depending on the complexity of the design and the number of items being produced.

4.4 Minimum Order Quantities

When considering screen-printed items, it’s important to note the cost considerations, especially for small orders. Lower minimum quantities can lead to higher prices, and typically, only one ink colour is included in the pricing, with additional colours incurring extra charges.

4.5 Design Flexibility

Embroidery relies on predefined thread colours, which can restrict design options. Unlike screen printing, which allows for mixing inks to create a broader spectrum of colours, embroidery may not achieve the same level of colour variety and visual effects.

Design style

Embroidery excels at intricate details, adding depth and texture to designs, but can struggle with small text or complex colour gradients. Screen printing can produce bold, simple designs and sharp images but is less effective for intricate designs requiring multiple colour gradations.

Fabrics

A versatile technique, embroidery works well on a wide range of fabrics, including cotton, polyester, denim and blends, as well as heavier fabrics for jackets and hats. Polo shirts are particularly adaptable for custom embroidery due to their thicker fabrics and structure, making them ideal for both professional and casual settings. Stitching is less effective on thin, stretchy materials. Screen printing is best suited for natural fabrics like cotton, but some synthetic and textured fabrics can struggle to hold the ink.

Durability

One of the main benefits of using embroidery is that it can withstand frequent washing and heavy wear without fading or peeling. Screen printing designs are durable when properly cured, but the print may fade or crack over time.

Cost

More expensive for smaller quantities, embroidery requires more setup and labour. Screen printing is often cheaper for bulk orders because the setup cost reduces with the quantity of items.

 Texture

With a raised, textured finish embroidery adds a tactile, 3D effect to the garment. However, the design might be noticeable on the inside of the garment. Screen printing produces a smooth finish with the ink being applied directly on the fabric, which can make it feel more comfortable against the skin.

Making the right choice between embroidery vs screen printing

Now you know the key differences between embroidery vs screen printing, you can establish the key factors that will influence your final decision:

  • Budget: embroidery is great for smaller volumes, while screen printing gets cheaper as the order volume increases.
  • Design: the colours and complexity of the design will lend itself to a particular method. Do you want an intricate finish or bold colours?
  • Fabric: your choice of material is important to get the perfect finish.
  • Branding: embroidery is perceived as being more traditional and professional, while screen printing is seen as modern and dynamic.
  • Durability: A screen printed shirt may face issues with durability, such as cracking or chipping of the design when washed or exposed to high temperatures. To preserve the screen print quality, it is recommended to handwash the garment and keep it away from heat.

Applications for embroidered logos vs screen printing

In summary, embroidery is ideal for companies requiring smaller quantities with an intricate and durable design. Embroidered garments are particularly appropriate for professional settings due to their premium appearance and comfort. Stitching creates a classic look across a range of fabrics, including heavier garments, that enhances a brand’s perception as high-quality. The perfect choice for workwear, uniforms, hats, bags and detailed designs.

Screen printing is preferred by businesses needing cost-effective solutions for large quantities. Ideal for producing bold, simple designs on natural fabrics, ink projects a dynamic brand image and is suitable for various industries. Best used for t-shirts, hoodies, large designs, bold colours and bulk orders.

If you have a question about using embroidery and screen printing for your corporate clothing, talk to the friendly and professional team at Positive Branding. Click here to get a FREE quote.