Embroidery vs Screen Printing: What to Choose

Embroidery vs screen printing is one of the most common comparisons when choosing how to decorate custom apparel. Both methods create professional, long-lasting designs, but they differ in texture, cost, and best use.  

Embroidery stitches thread directly into fabric for a textured, premium look, while screen printing uses ink to produce bold, smooth designs. Each method shines in different situations depending on your material and design style.  

In this guide, we’ll break down embroidery vs screen printing step by step, helping you decide which technique fits your project and budget best.

Understanding Embroidery And Screen Printing

Embroidery uses colored threads to craft designs right into the fabric with precise stitches. Screen printing pushes ink through mesh screens to lay designs on top of garments. The way each process works, the equipment they use, and where they really shine—it all affects how your final product turns out.

How Embroidery Works

With embroidery, designs are stitched directly into fabric by computerized machines. It all starts with digitizing your design into a special file that guides every stitch.

Modern machines can switch thread colors automatically using multiple needle heads. The machine moves the fabric around in tight, programmed patterns while the needles punch thread through.

Stitch count tells you how many stitches your design will need. Simple text might be 2,000–5,000 stitches; detailed logos can hit 15,000 or more. More stitches mean more time and higher cost.

Machines use different stitch types for different effects: fill stitches for big areas, satin stitches for smooth edges, and running stitches for outlines.

Thread quality matters. Polyester thread is tough and holds color well. Rayon gives more shine but isn’t quite as strong.

How Screen Printing Works

Screen printing uses mesh screens to press ink onto fabric. Each color in your design needs its own screen, which gets coated with a light-sensitive emulsion.

The design is burned into the screen using bright lights and a film positive, creating open spots for ink to pass through and blocked spots where it won’t.

During printing, ink sits on the screen and a squeegee pushes it through the open mesh onto the fabric. After printing, the fabric runs through a heat tunnel to cure the ink for good.

There are different inks for different jobs. Plastisol is bright and works on most fabric. Water-based inks soak in for a softer feel. Discharge inks actually remove the shirt’s original color and swap in new shades.

Screen printing is built for bold, vibrant colors and can handle pretty complex, multi-color designs once the screens are set up.

Main Differences Between The Two Methods

The biggest difference with embroidery vs screen printing is how they put designs on fabric. Embroidery uses raised threads for texture, while screen printing lays flat designs on top of the material.

Embroidery is best for sturdy fabrics like polos, jackets, and hats. On thin material, the stitching can cause puckering or distortion. Screen printing plays nice with almost any fabric, from light t-shirts to heavy hoodies.

Cost is a big factor. Embroidery pricing is mostly about the stitch count and doesn’t shift much with order size. Screen printing has higher setup costs but gets way cheaper per piece if you order a lot.

Durability? Embroidery stands up to fading, but threads might break or fray over time. Screen prints hold up well through lots of washes if they’re cured right.

Comparing Quality, Cost, And Durability

Embroidery gives you a raised, professional look and works best for smaller orders, though it costs more up front. Screen printing delivers vibrant color at a lower price per item—if you’re ordering in bulk. Both can be durable, but they need different care.

Appearance And Texture

Embroidery has that premium, three-dimensional look. You can feel the stitches. It’s a classic choice for logos and simple designs.

The thread gives a bit of shine and depth. It just looks sharp on polos, jackets, and hats—no wonder so many businesses go this route.

Screen printing? Totally different feel. Designs are flat and smooth, the ink just sits on top. You get those poppy, bold colors.

Screen printing is better for complex art. You can print detailed images, gradients, even photos. Big, loud designs are right at home here.

The feel depends on how much ink is used. Lighter prints are soft, but if there’s a lot of ink, it can feel a bit thicker, though still smooth.

Cost Per Item And Setup Time

Embroidery costs more per piece but doesn’t have setup fees. You pay for stitch count and thread colors. Simple logos are cheaper; detailed ones run up the bill.

Embroidery is the way to go for small orders. You don’t get hit with setup costs like you do in screen printing. For 12–50 pieces, embroidery often wins on price.

Screen printing needs a screen for every color. Setup runs $15–$50 per color, but spread that across a big order and it’s not so bad.

Screen printing dominates on big orders. Once you’re at 100+ pieces, the price per shirt drops fast. That setup fee becomes a non-issue.

Screen printing is also quicker for big batches—one screen can print hundreds of shirts in no time. Embroidery is slower since every item gets stitched one at a time.

Durability And Maintenance

Embroidery holds up well against daily wear. The thread becomes part of the fabric. You can wash embroidered stuff normally—just use cold water and skip the bleach. Those stitches hang in there for years if you treat them right.

Screen prints need a little more TLC. Flip shirts inside out before washing, go with cold water, and keep the dryer heat low.

Good screen printing can last 50+ washes. Cheap ink cracks and fades fast, but a good shop with proper curing? You’ll get plenty of mileage.

Both methods will fade in the sun over time. Embroidery thread might fray at the edges if you really put it through the wringer. Screen prints can crack if you stretch the fabric too much.

Choosing The Right Method For Your Project

Embroidery’s your go-to for professional gear and small quantities. Screen printing is king when you need lots of items with colorful designs. It really comes down to your budget, how detailed your design is, and how you’ll use the gear.

When To Use Embroidery

Pick embroidery for uniforms, corporate polos, and dress shirts. The raised stitches just look sharp—great for business settings.

Best for small orders: No minimums here. You can do just one piece without paying a fortune to set up.

Super durable: Thread-based designs hold up through tons of washes. Perfect for uniforms that need to last.

Keep it simple: Stick with:

• Bold text
• Simple shapes
• Few colors (six or less)
• No tiny details

Embroidery costs more per item but gives you top-notch quality. Expect to pay $3–$15 each, depending on size and complexity.

Works on most fabrics: Cotton, polyester, fleece, performance fabrics—you’re good. Thick stuff like jackets and hoodies really show off embroidery.

When To Use Screen Printing

Screen printing is the obvious pick for big runs, t-shirts, or when you want a lot of color. If you need 50+ pieces or eye-popping graphics, this is your method.

Cheap for big batches: Setup costs get divided across all the pieces. For 100+ shirts, you’re looking at $2–$8 each.

Great for detailed art: Screen printing nails:

• Photos
• Intricate artwork
• Gradients and shading
• Unlimited color options

Best on cotton: Cotton and blends take ink best. The smooth surface means crisp lines and bright colors.

Big designs welcome: You can cover the whole shirt if you want—no size limits like embroidery.

Screen printing usually comes with minimums—most shops want at least 24–50 pieces to make it worth their time.

Getting Started With A Screen Printing Kit

If you want to try screen printing at home, basic kits are out there. They come with screens, squeegees, and water-based inks—enough for simple projects.

What you’ll need:

• Pre-stretched screens (110–160 mesh)
• Photo emulsion and sensitizer
• Squeegees (various sizes)
• Water-based inks

Vinyl stencils for basic designs

Setup tips: You’ll need a dark spot for exposing screens and decent ventilation for drying. A basement or garage is usually fine.

Start with single-color designs on light shirts. Water-based ink is easier for beginners than plastisol. Practice on some old tees before you go for the final product.

DIY limits: Home kits struggle with multi-color jobs and big quantities. Pros have better gear for tricky stuff.

Figure on $200–$500 for a solid starter kit. Don’t forget to budget for your learning curve and supplies when weighing DIY against hiring a shop.

Conclusion: Embroidery vs Screen Printing

Both embroidery and screen printing have their strengths—it all depends on your design, fabric, and budget. Embroidery delivers a classic, high-end look that lasts, while screen printing offers bright colors and flexibility for larger orders.  

If you’re unsure which to choose, think about where your design will go and how it’ll be used. Either method can make your custom apparel stand out with the right approach.  

Looking for more creative inspiration? Check out our next post for fun, family-friendly projects: Summer Craft Ideas for Kids.

Frequently Asked Questions: Embroidery vs Screen Printing

Embroidery uses thread and needle to make raised designs that last through tons of washes. Screen printing uses ink and stencils for flat, colorful prints—great for big graphics and bulk orders.

Is embroidery or screen print better?  

It depends on your project. Embroidery gives a polished, textured look for logos and uniforms. Screen printing is best for bold, colorful designs and large orders.  

What lasts longer, screen print or embroidery?  

Embroidery usually lasts longer since the thread is stitched into the fabric. Screen prints can fade or crack over time with repeated washing. With proper care, both can stay vibrant for years.  

What are the disadvantages of embroidery?  

Embroidery costs more and takes longer for small batches. It doesn’t work well on thin or stretchy fabrics. Large designs can feel heavy or stiff to wear.  

What is the difference between embroidery and printing?  

Embroidery stitches thread into fabric for a raised, textured design. Screen printing applies ink on top for a smooth, flat finish. Embroidery looks premium and durable, while printing offers more color options and detail.