Embroidery is NOT a one to one replacement for printing, patches, or heat transfer vinyl lettering.
Although embroidery is done with needle and thread, there is a limit to the amount of stitching any fabric can hold. Logos, Text, or Artwork in excess of 10,000 stitches may cause slight pulling on the surrounding fabric, especially on very lightweight, stretchy, loose or open weave fabrics like most T-Shirts, Lycra, Spandex, polyester knits/blends, polyester mesh, terry cloth or rayon fabrics.
Choosing The Right Fabric
Embroidery will always look best on strong, closely knit fabrics. Open knits or loose knits such as “jersey knits”, lightweight piques, waffle knits, rib knits, or similar fabrics, are uneven. They may cause thin or small lines and letters to sink down into the fabric or get lost in the weave because there is not as much fabric to hold the close stitching together.
Embroidery of More Than 10,000 Stitches
Embroidery thread is heavier, stronger and a tighter density than the surrounding fabric. If your project requires large, dense embroidery of more than 10,000 stitches, please select heavyweight fabrics with an ounce weight higher than 7 ounces. Alternatively, select high-quality fabrics with tight weaves including denim, double pique, oxford cloth, cotton canvas, poplin, twill, wool, flannel, fleece or microfiber.
Try to avoid the least expensive shirts you can find for large stitch count embroidery; there is a reason why low-priced shirts are low-priced. The quality of the knit is barely able to hold the shirt together, let alone 10,000+ stitches. If your shirt costs less than the embroidery, think twice. Many inexpensive polo shirts use the term “Jersey Knit” — which is nothing more than a T-Shirt with a collar. Jersey Knits are not suitable for large embroidered logos of any kind.