Print methods
Embroidery for workwear & merch
Embroidery is the premium choice for logos that need to look sharp, feel substantial and last as long as the garment. We run Happy Japan industrial embroidery machines, a leading industry standard, to stitch crisp, colour-accurate designs into polo shirts, softshells, caps, hoodies, towels and more, with no minimum order quantity.
How embroidery works
01
Artwork setup
Your logo is converted into a stitch file (digitising). We map thread colours, densities and stitch directions so the design sews cleanly on your chosen fabric without puckering or gaps.
02
Frame & stabilise
The garment is held taut in a hoop with backing material underneath. Proper tension and backing stop the fabric from shifting and give the stitches a crisp, even finish.
03
Machine embroidery
Happy Japan industrial embroidery machines sew the design directly into the fabric. Each needle carries a different thread colour, so multi-colour logos change threads automatically.
04
Finish & inspect
Excess backing is trimmed, threads are checked, and every piece is inspected for tension, alignment and finish before it is packed.
Digitising your logo
Before an embroidery machine can sew your design, the artwork has to be converted into a stitch file, a process called digitising. A skilled digitiser interprets your logo and decides exactly how each element should be sewn: stitch direction, density, underlay, pull compensation, thread colours, and the order in which the machine runs.
It is not the same as saving a JPEG as a different file type. The digitiser has to understand how different fabrics behave, how stitches pull and push, and how to keep fine detail crisp without the thread bunching or the fabric puckering. A poorly digitised file will look loose, misaligned, or wear out quickly; a well-digitised one will look sharp and last as long as the garment.
We outsource digitising to specialist embroidery studios whose full-time job is stitch programming. That means every file is produced on professional-grade software and tested on real machines before it reaches production. Their expertise is why we can promise consistent, high-quality results.
Why there is a small charge
Each design is programmed by hand, and the time depends on the size and complexity of the logo. There is a one-off digitising fee for new artwork, typically around £15. Once your file is ready, it can be reused on future orders without paying the fee again.
Reusable for every order
The digitised file is stored against your account, so reorders, different garment styles, and new team members can all use the same approved stitch file. You only pay the digitising fee once per design.
Why we recommend it
Premium, professional look
Embroidery adds texture and weight that printed finishes cannot match. It is the standard for corporate polo shirts, softshells, caps and hospitality uniforms.
Built to outlast the garment
Stitched threads sit inside the fabric rather than on top of it. A well-digitised embroidered logo will usually survive the garment itself, with no cracking or peeling.
Works on tricky fabrics
Fleece, piqué polo, softshell, canvas, denim and heavy cotton all take embroidery well. It is often the only custom option that looks smart on textured materials.
Fine detail when digitised well
Small text down to around 5mm, thin outlines and layered colour blocks can reproduce cleanly with the right stitch type and density.
No minimum order quantity
Whether you need one embroidered cap or five hundred polo shirts, the setup cost is the same per design, making it economical for small runs and reorders alike.
Fast, consistent production
Multi-head Happy Japan machines run several garments at once, so once the design is approved, repeat orders are quick and identical every time.
Colours & detail
We use Madeira and other high-quality polyester embroidery threads that hold colour through washing, sunlight and heavy wear. Most brand colours can be matched accurately from Pantone or thread references, and multi-colour designs are handled by the machine changing needles automatically.
Happy Japan machines are known for precise, consistent stitching and high-speed production without sacrificing quality. That means sharp edges, even fills and reliable registration across every garment in a run, from the first piece to the last.
For the cleanest result, send vector artwork (AI, EPS, PDF or SVG) or a high-resolution PNG. Very fine text, hairline details and small gradients are better simplified slightly before digitising. We will advise if any part of your logo needs adjusting for embroidery.
Artwork we can work with
Vector files are best. If you only have a raster image, make sure it is high resolution and at the size you want it embroidered. We digitise the design into a stitch file and send a preview for approval before production.
Sizes & placements
Typical embroidery placements and sizes. Larger designs cost more because they take longer to sew and use more thread, but the finish is worth it for bold branding.
| Placement | Typical size | Best for |
|---|---|---|
| Left chest | 8–10cm wide | The classic position for polo shirts, work shirts and softshells |
| Centre chest | Up to 15cm wide | Larger crests, badge-style logos and club emblems |
| Cap front | 5–7cm wide | Curved designs need a special cap frame for clean registration |
| Sleeve | 6–10cm wide | Sleeve badges, pennants and brand marks |
| Large back | Up to 25cm wide | Big crests, club names or event branding on jackets and hoodies |
| Towels & bags | Various | Thick towels and canvas bags can take dense, high-impact designs |
Left chest logos are the most popular and cost-effective size. Large back designs make a strong statement but take more machine time, we will quote based on stitch count once the design is digitised.
How long it lasts
Embroidery is one of the most durable decoration methods available. Because the thread is stitched through the fabric, it does not crack, peel or fade like surface prints can. It flexes with the garment, survives industrial laundry cycles, and often looks better after years of wear.
The backing and stabiliser we use are chosen for the fabric type, so even heavy cotton or stretch piqué keeps its shape around the design. For high-wear workwear, we can add extra underlay or a denser fill to keep the logo looking solid.
Years
Typical lifespan
50+
Wash cycles easily
No MOQ
One cap or one thousand
Care guide
- Embroidery can be washed at the garment's recommended temperature, typically 30–40°C.
- Turn garments inside out to reduce friction on the stitched surface.
- Avoid bleach and harsh detergents that can dull thread colours over time.
- Tumble dry on low or line dry; high heat can shrink the fabric around the stitches.
- If ironing, press on the reverse or use a pressing cloth over the embroidery.
Embroidery vs DTF vs vinyl
Embroidery
Premium stitched finish. Best for corporate workwear, caps, polos and any design that needs to look smart and last for years.
DTF print
Full colour, photographic detail and soft feel on almost any fabric. Great for merch, complex artwork and multi-colour logos.
Vinyl transfer
Cut solid colour for names, numbers and short personalisation runs. Ideal when each garment needs different text.
Not sure if embroidery is right for your logo?
Send us your artwork and the garments you have in mind. We will recommend the best method, advise on sizing and placement, and give you an honest quote, including a one-off digitising fee if your design has not been embroidered before.