Screen printing and embroidery are the two most common decoration methods for custom apparel. Together, they cover 80% of all logo-decorated apparel in the world. They look different, cost different, and last different — and choosing the right one for your project can save you money and get you a better result.
01.Screen Printing: The Workhorse
Screen printing pushes ink through a fine mesh screen onto fabric, one color at a time. It is the most cost-effective method for high-volume runs with limited colors (under 6). Plastisol ink sits on top of the fabric (vibrant, durable, slightly raised). Water-based ink dyes the fabric (soft hand, vintage look).
Best for: band merch, sports team uniforms, corporate giveaways, event t-shirts. Works on most fabrics. Cost-effective at 200+ pieces. MOQ 50 pieces. Lead time 10-20 days.
02.Embroidery: The Premium Choice
Embroidery stitches the design into the fabric using threads of precise Pantone-matched colors. The result is a raised, textured, professional look that conveys quality. Stitches last the life of the garment — no fading, no peeling, no cracking.
Best for: corporate logos on polos and caps, sports team caps, premium retail, club merchandise. Works on caps, polos, jackets, bags, patches. Cost-effective at any run size. MOQ 50 pieces. Lead time 10-20 days.
03.Cost Comparison
Screen printing: lower per-piece cost at high volume. Setup cost ~$30-50 per color. Best price per piece at 500+ piece runs.
Embroidery: higher per-piece cost but flat regardless of volume. Setup cost ~$25 one-time digitizing fee. Best value at 50-200 pieces.
For a 500-piece run of a 2-color logo on cotton t-shirts: screen print is ~$3-4 per piece, embroidery is ~$5-7 per piece on a polo.
04.When to Use Each (and When to Combine)
Use screen printing for: bold graphics, large designs, all-over or chest prints on cotton/garment-dyed tees, anything under 6 colors at 200+ pieces.
Use embroidery for: logos on polos, caps, jackets, bags, patches, premium corporate apparel, anywhere you want a stitched-in quality look.
Combine them: many premium garments use embroidery for the chest logo and screen print for the back design. This is the most common setup for sports team uniforms and corporate wear.
?Frequently Asked Questions
Is screen printing cheaper than embroidery?
Yes, for most apparel orders, screen printing is cheaper per piece than embroidery — especially for large runs and multi-color designs. Screen print cost is driven by the number of colors and setup screens, not the number of pieces. Embroidery cost is driven by stitch count and number of pieces, so it gets expensive fast on large runs.
Which lasts longer, embroidery or screen printing?
Embroidery typically lasts longer. Embroidered logos are stitched into the fabric with thread — they cannot peel, crack, or fade even after hundreds of washes. Screen printed logos are a layer of ink on top of the fabric, so they will eventually crack or fade after 50-100+ washes. For a uniform that needs to look sharp for 3+ years, embroidery is more durable.
What is better, embroidery or screen printing?
It depends on the design. Embroidery is better for: small logos, premium feel, polos, hats, jackets, uniforms that need to last 3+ years. Screen printing is better for: large graphics, multi-color designs, photos or gradients, t-shirts, hoodies, budget orders. Many of our customers combine both: embroidery on the left chest + screen print on the back.
When to use screen printing vs embroidery?
Use screen printing when the design is large (over 4 inches wide), multi-color, or photographic. Use embroidery when the design is small (under 4 inches), 1-3 colors, on a polo/hat/jacket, and the brand wants a premium stitched feel. For corporate uniforms, most orders use both: embroidered logo on the chest + screen print on the back.
Can you do both screen print and embroidery on the same garment?
Yes — and it's very common. A typical setup: embroidered left chest logo (small, premium feel) + screen printed large back design (brand or event graphic). We do this for most of our corporate uniform and event merchandise orders. The pricing is straightforward: embroidery cost per piece + screen print cost per piece, no extra setup fee for combining.
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