When you're ordering branded apparel for your team, one of the first decisions you'll face is decoration method. Embroidery and screen print are the two most common choices — and they're not interchangeable. Here's a clear breakdown of when to use each.
What is embroidery?
Embroidery is thread stitched directly into the fabric. It's dimensional, durable, and has a premium look that reads as professional. It's the standard for polos, jackets, hats, and outerwear — anything that needs to hold up through repeated wear and washing.
What is screen print?
Screen print uses ink pushed through a mesh stencil onto the fabric. It's flat, vibrant, and cost-effective for larger quantities. It's the standard for t-shirts, event shirts, and anything where you need bold color at a good price per piece.
There's also DTF (direct-to-film), which is a newer alternative to screen print that works well for smaller runs and complex artwork. Read more in our guide on DTF vs screen print.
When to choose embroidery
- Polos and dress shirts — embroidery is the professional standard
- Jackets and outerwear — holds up better than print on heavier fabrics
- Hats and caps — embroidery is the only practical option for structured headwear
- Customer-facing uniforms — the dimensional look signals quality to customers
- Long-term uniform programs — embroidery outlasts screen print by years
When to choose screen print
- T-shirts — screen print is the standard for a reason
- Large quantities — cost per piece drops significantly at volume
- Full-color artwork — complex logos with gradients are easier to screen print than embroider
- Event shirts — one-time use items where cost matters more than longevity
- Large back prints — you can't embroider a 12-inch back design economically
What about mixing methods?
You can absolutely combine both. A common corporate approach is embroidered left chest logo on a polo plus a screen printed back with a tagline or contact info. Talk to your printer about what makes sense for your specific order.
See our guide on screen print vs embroidery for work uniforms for a trades-specific perspective.
Cost comparison
Embroidery setup costs more upfront (digitizing your logo into a stitch file), but the per-piece cost is relatively flat regardless of quantity. Screen print has lower setup costs but the per-piece cost drops significantly as quantity increases.
For small orders of 12-24 pieces: embroidery and screen print are often comparable in cost.
For large orders of 72+ pieces: screen print typically wins on price per piece.
💡 If you're not sure which to choose, tell your printer what the garment is and how it'll be used. A good shop will tell you honestly which method makes more sense — not just which one costs more.
What about your logo?
Complex logos with thin lines, gradients, or lots of detail can be tricky to embroider. Your printer will digitize your artwork into a stitch file and may simplify some elements. This is normal. Read our guide on how to prepare artwork for custom shirt printing to understand what makes a logo print-ready.
Ready to place your order? Call 855-TSHIRT-5 or request a quote online.