When it comes to custom apparel, workwear or promo products, three main methods rule the industry: embroidery, heat-seal (also known as heat transfer), and screen printing. Each method has its own Pro's and Con's to consider. In this guide, we’ll explore these in detail, helping you make a more informed choice for your next project.

Embroidery

Embroidery involves stitching a design directly into fabric using a needle and thread. This method creates that familiar 3D look and feel, often thought of as a sign of high quality.

How It Works

• Design: The logo or design is first converted into a file (such as “.jef”, “. sew” and “.jan”) that embroidery machines can read.
• Setup: The area that is to be stitched on is placed into a plastic hoop that keeps it firmly in place and taut to prevent creases. The embroidery machine is then threaded with reels of fabric, picked from a set range of colours that can also include textures and various thread thicknesses.
• Stitching Process: The machine stitches the design into the fabric in much the same way as a sewing machine does. The main difference is that an embroidery machine can move the fabric around the X and Y of the needles position automatically. This makes it safer and quicker than manual operating.

Best Uses

• Workwear and Custom Apparel: Ideal for uniforms, corporate wear, and high-end garments. The durability and professional look of embroidery make it a popular choice for company polos, jackets, shirts and hats.
• Small Designs: Best suited for smaller designs like logos or monograms.
• Premium Products: Items like towels, bags, and caps often use embroidery to convey a sense of luxury.

Pros

• Durability: Embroidery is resistant to fading and fraying, making it ideal for items that will undergo frequent washing and use.
• Premium look: The raised texture and sheen of embroidered thread give a high-quality look and feel.
• Design: Suitable for very intricate or small details.
• Colour Variety: There are hundreds of colours to choose from and a wide range of threads including cotton, silk, rayon, linen, wool and metallic.

Cons

• Cost: More than other methods, especially for large designs or those with a lot of colours.
• Limited Fabric Options: Works best on thicker fabrics like cotton, fleece, or denim; thinner or stretchy materials like t-shirts can “pinch” around the stitches making the result look bad.

Heat-Seal (Heat Transfer)

Heat-seal, or heat transfer printing, involves placing a design onto fabric using heat and pressure. This method is highly versatile, allowing for complex and colourful designs.

How It Works

• Design Creation: The design is printed onto a special transfer paper using either inkjet or laser printers or cut from a sheet of vinyl using a plotter.
• Heat and apply: Transfer paper or vinyl is placed over the area you want the design to go, and a machine applies heat and pressure to bond it onto the fabric.

Best Uses

• Sportswear: Often used for jerseys, team shirt numbers, and names due to its ability to adhere to stretchable materials.
• Custom T-Shirts: Perfect for small batches of custom t-shirts, especially when full-colour images or complex designs are needed.
• Promo Items: Heat Presses are often used for items like tote bags, mouse-mats, and almost any other promotional product with a suitable surface.

Pros

• Versatile: Can be used on a wide range of materials, including cotton, polyester, and blends.
• Detail and Colour: Allows for high-detailed, multi-coloured designs, and even photo-realistic prints.
• Low Setup Cost: Heat Sealing doesn't require an extensive setup.

 Cons

• Durable: The design can crack or peel over longer periods of time.
• Feel: The transfer can sometimes have a rubbery or stiff feel, which might not be desirable on all garments.
• Colour: There can be slight variation in colour matching due to the conversion of CMYK from pantones and the colour of the fabric used.

Screen Printing

Screen printing, also known as silk screening, is one of the oldest and most popular methods for printing on custom apparel. It involves pushing ink through a stencil (or screen) onto the fabric, creating a vibrant, long-lasting design.

How It Works

• Screens: A mesh screen is coated with a light-sensitive emulsion and exposed to light through a film of the design, creating a stencil.
• Ink: The screen is placed on the fabric, and ink is pushed through the stencil using a squeegee.
• Curing: The ink is cured using heat to ensure it sticks to the fabric.

Best Uses

• Bulk Orders: Ideal for large quantities due to its cost-effectiveness and speed.
• Simple Designs: Works best with bold, simple designs that use a limited number of colours.
• Custom Apparel: Commonly used for t-shirts, hoodies, and other apparel where vibrant, long-lasting prints are needed.

Pros

• Durable: The ink used in screen printing is thicker and more durable than that used in other methods, making it long-lasting and resistant to fading.
• Vibrant Colours: Screen printing produces bright, bold colours, even on dark fabrics.
• Cost-Effective: Especially for large batches with simple designs.

Cons

• Setup Time and Cost: The initial setup is time-consuming and costly, making it less suitable for small orders.
• Limited Colour Use: Each colour requires a separate screen, so multi-coloured designs can become expensive and complex to handle.
• Environmental Concerns: The process involves chemicals and water, that need to be managed properly.

Compare the Three Methods

Durability

Cost

Detail and Complexity

Fabric Compatibility

 Choosing the Right Method for Your Project

When selecting between embroidery, heat-seal, and screen printing, consider the following factors:

• Quantity: For large orders, screen printing is often the most cost-effective. For small batches, heat-seal might be better.
• Design: If your design is complex and colourful, heat-seal might be the way to go. If it’s a simple logo, embroidery or screen printing could be ideal.
• Fabric: Consider the material you’re working with. Embroidery is great for sturdy fabrics, while heat-seal and screen printing are more versatile.
• Budget: Factor in the setup and costs. Embroidery and screen printing have higher setup costs but heat-seal can be more economical for smaller orders.

We’re happy to help!

Whether you're outfitting workwear for a team, creating your own promo products, Custom Apparel, or managing an event, we’ll help you choose the right method to make all the difference in achieving the perfect look and feel for your brand.