Pricing Embroidery Stitch Count

Custom Embroidery Pricing

Last Updated: 09-27-2021

So you're ready to order custom embroidered shirts or hats with your company logo.

A major driver of cost with embroidery is the stitch count of your design. Unlike with screen printing that calculates cost by print colors.

What does this mean?

Each custom embroidery design is communicated to our embroidery machines via an electronic file that guides each needle with a precise location, pattern, and thread color to be used for each element of the design.

This program is a computerized mapping of coordinates for each and every element in the custom embroidered design. The process of converting a design to this program is called digitizing.

Digitizing is the first and most important step in the custom embroidery design process. Great digitizing will ensure that the image is mapped properly and efficiently, meaning it will sew well during production and look great when finished.

What is a stitch count and how is it determined?

A stitch count is a precise measurement of thread usage required for custom embroidery of a specific image.

Stitch count is determined after an image is converted into an electronic format that can be read by an embroidery machine.

How does stitch count effect my custom embroidery prices?

All prices shown on our site include a 5000 (5k) stitched embroidery image.

Once the custom embroidery design is converted to the electronic format, the total thread usage is determined.

The total thread usage tells us how long it will take to embroider each design; essentially it equates to the labor and raw materials cost.

A higher stitch count will definitely increase your cost because our costs have increased as well.

We will ALWAYS notify you when the stitch count is higher. Informing you of the additional cost to proceed.

Can I guesstimate my stitch count?

Depending on how in-depth you want to get, the answer is yes.

Quick & Easy Way (but not 100% accurate)

Using the dimensions of your logo, use this formula:

Example: logo is 3" wide by 2" high.

3 x 2 = 6

x2 (width x height)

6 x 2 = 12

approx. 12k stitches

Benefits of using this method:

(1) Fast

(2) Fairly simple

(3) Most often will overestimate the stitch count.

(4) If the stitch count is overestimated; you come in under budget :)

Downside of using this method:

(1) It is not accurate.

Custom Embroidery Caps

Design Custom Embroidered Hats

Last Updated: 09-27-2021

Here are the best reasons to add your logo or message to a cap.

Everyone can wear them.

No need to mess with sizes (most of the time).

Lightweight and portable.

Feels more extravagant than a t-shirt giveaway.

Let's dig right in.

There are two really important facts about hats that won't change:

1. A hat's surface isn't flat.

2. The area to embellish on a cap is a small.

We want your custom embrodiery caps to be something you're proud to wear and to give to others to wear. Unless you're buying thousands of caps and have a few months to wait, chances are you'll be embroidering your logo or message on a finished cap.

This is where the "flat surface" and "small space" enter the conversation.

If you were going to draw a picture or write a note, you'd grab a pencil, a piece of paper, and look for a flat surface. Writing on a flat surface will likely make your message clearer and more legible.

Recognizing that our cap is not flat, we want to minimize illegibility issues that are more likely to occur because we are working on a curved surface.

The areas that we can embroider on a cap are small.

Most common area to add a logo or message is the front:

Average Max size is 4" x 2" (width by height).

This is what 4" x 2" area looks like on a cap.

It seems small when thinking of just the dimensions, but when

seen in real life the size is appropriate.

Before we can embroider onto the cap. We need to hold the cap as tightly in place as possible. We use a specialized frame that works specifically with our machines for this purpose.

cap secured in the specialized frame

Although the cap has been assembled on the frame correctly, there are parts that can't be secured tightly.

Looking at the picture below, notice the center of the cap at the base of the cap where the crown meets the bill. You can see the areas that begin to pucker.

front of the cap with frame

This area and the front center seam of the cap are the danger zones. For best results, it's important to limit small text that's located near the bill of the cap. When logos include small text positioned at the bottom of a design, it is necessary to reduce the overall height to 4" x 1.8".

Small details and thin lines that are positioned on or near the center seam can create legibility issues. In this area, we'd strongly advise against the use of thin outlines that surround small objects (text or images).

Once we have the caps secured into their frames, they are locked in place onto the embroidery machine.

hand is pictured at the top of the frame

cap is secured below the embroidery needles

Here's our advice for great looking hats that you will be proud to wear:

1. Understand physical limitations.
2. Be brief & make it bold.
3. Avoid small text.
4. Use additional locations, if extra space is needed. However, keep in mind it does cost more.

Here are some examples of do's and dont's for getting the best quality and best priced embroidery hat design:

Example 1 - Front of Cap

(left) Original "boltprinting & embroidery" company name embroidered on front of hat

= design is too detailed for a clean quality embroidery.

(right) Simplified version of "boltprinting & embroidery" is cleaner and better for embroidery.

front embroidered logo hat

Example 2 - Front of Cap

(left) Bolt 'Lightning' icon embroidered on front of hat

= design is large and expensive.

(middle) Reduced size of 'lightning' icon = good sized icon, less expensive than (left) option and is it still has an impact.

(right) Smallest size is the least expensive and also the most subtle.

front embroidery logo hat

Example 3 - Corner of Cap

(left) "boltprinting & embroidery" company name embroidered on corner of hat

= design is too large and detailed for the small area and expensive.

(middle) Bolt 'Lightning' icon = using the lightning bolt icon instead of the company name is definitely a better option, but this size is a bit large for the small area.

(right) Smaller size of the 'lightning' bolt icon is the best choice and also the least expensive.

embroidery design on corner of hat

Example 4 - Side of Cap

(left) "boltprinting & embroidery" company name embroidered on side of hat

= design is too large and detailed for the small area and expensive.

(middle) Bolt 'Lightning' icon = using the lightning bolt icon instead of the company name is definitely a better option, but this size is too large for the small area.

(right) Smaller size of the 'lightning' bolt icon is the best choice and also the least expensive.

side embroidered hat design

Example 5 - Back of Cap

(left) Original "boltprinting" company name embroidered on back of hat

= design is too large and detailed for this area and expensive.

(middle) Simplified version of "boltprinting" is definitely a better option the than the original for embroidery on back of hat.

(right) Average size of the 'lightning' bolt icon is the best choice and also the least expensive.

embroidered design on back of hat

Custom Embroidered Shirts

Custom Shirt Embroidery

Last Updated: 09-27-2021

Are you ready to order Custom Embroidery Designed Company Shirts?

Embroidery is a distinct and unique method of embellishment. Embroidered polo shirts with logo design are brand builders. Commonly regarded as prestigious and professional, they are often worn by administrative personnel, sales teams and senior executives. In comparison to a screen printed polo; an embroidered polo carries a higher perceived value.

We want your custom embroidery designed company polo shirts to be worn with pride. Understanding the design and production process guides us to implement best practices and develop realistic expectations.

Embroidery has rules and limitations. Acceptance of the limitations works to your advantage, fighting them is a recipe for disappointment.

Let's Get Started.
Embroidery by definition is the art or process of forming decorative designs with machine needlework.

Our embroidery machines are computer controlled and specifically engineered for embroidery. We utilize a hooping system that holds the framed area of fabric taut under the sewing needles and moves it automatically to create a design from a pre-programmed digital embroidery pattern.

The embroidery pattern that directs the machine is created using specialized software by skilled production artists. This process is called digitizing and is the most important building block for everything that comes next.

Technical Limitations + Fabric Type + Garment Size

Variable factors that dictate what is possible.

Styling and design of logos that look best embroidered:

Bold and simplistic imagery in distinct colors.

A company name is not always necessary, especially when graphic elements carry the message.

Technical Limitations

Physical boundaries are necessary to maximize legibility.

The smallest letter height for embroidery for it to be legible is .25" - .30"
The standard width of a left chest image on a polo is 3" - 3.5".

(if you are ordering small sizes, we suggest that you do not exceed 3")

See below how letter size effects line length, legibility and fabric style.

Textured / Pique Fabrics

Flat / Jersey Fabrics

Remember the standard width of a left chest logo when embroidered is 3" - 3.5" (4" pushes the boundaries, as it will look TOO big on smaller sizes).

When incorporating text in to your custom embroidery design, understanding the minimum letter height required and how this impacts line length, is often where potential issues arise.

Using one of the text examples above:

Scenario: a graphic or icon is placed at the beginning or end of the text line.

This will not work, because the width of the design is 4.8" .

(remember absolute max width is 4")

How to Resolve or Work Around:

Solution 1: Center the icon above the text line

OR

Solution 2: Icon placed to the left. Text displays on two lines.

Risky Logo Design Examples:

Color changes and thin outlines with a single element are inherently challenging.

These are likely to fall out of alignment during production.

Tiny details, thin lines, dots and fonts with serifs are difficult to retain clarity during production this can be intensified on textured fabrics (e.g. pique or mesh)

If fine details and clarity are must haves; your design might be better suited for screen printing.

Finer details can be controlled more effectively with this method.

When in doubt, ask for help.

We want your new custom embroidery design company shirts to elevate your status.

Custom Digital Printing

What is Digital Printing

Last Updated: 09-27-2021

Screen Printing vs. DTG

What is Digital Printing?

Digital Printing, DTG or Direct To Garment Printing all refer to a printing method where the machine prints directly onto the shirt using specialized machines and CMYK inks. Unlike screen printing which prints in spot colors, digital printing works with CMYK (Cyan, Magenta, Yellow, Black) colors. It is an affordable way to get custom printed shirts when you are purchasing a small quantity.

Digital printing started gaining momentum in the early 2000's; it was a monumental shift in the t-shirt world. Prior to this development ordering a small amount of t-shirts printed with multi-color graphics or photos would not be possible. The only option was transfer paper; it feels like paper that is ironed on a shirt; not a solution that gained popularity.

When a white shirt is digitally printed; the ink is absorbed into the cotton fibers. The shirt and ink become one and feels very soft.

When a dark shirt is digitally printed, the shirt is pre-treated with a transparent solution that is sprayed onto the t-shirt; this is necessary so that the ink is not absorbed into the fabric and it allows the print colors to be as vivid as possible. It will have a soft vinyl-like texture with a slight sheen to it.

See below a side by side example of the same design printed digitally and traditional screen print.

Royal Blue Ink Digitally Printed — Digital vs Screen Print Side-by Side Royal Blue on White Shirt

Benefits of Digital Direct Printing:

It makes purchases of small quantities affordable and possible.

Preferred choice for printing detailed artwork with multi-colors.
Excellent option for printing on dark colored t-shirts.
Digital printing is permanent and will not wash away when laundered.

Drawbacks of Digital Direct Printing:

Low quality art files may have a white outline around them.

Color matching is not possible and bright or neon-like colors will not be as vibrant.

Special inks such as metallic color or metallic silver ink colors are not possible.
Print consistency from shirt to shirt is less likely.

* Artwork printed by either method goes through the same review and proofing process by our experts.

Screen Printing Graphic Design

Screen Printing Locations

Last Updated: 10-12-2021

T-Shirt Printing Standards

As if designing a shirt is not challenging enough, now let's learn about some print lingo that will definitely come in handy when placing your order with us.

Print Location is WHERE you want your design to be LOCATED on the shirt. Often times customers think that because there are 2 pieces of art on let's say the front chest and the front bottom right, that this counts as 1 screen location but it doesn't. 2 locations = 2 separate screens, 3 locations (ex. front chest, back chest and sleeve print) = 3 separate screens.

Print Placement is the measurement used to determine the exact placement of the artwork. Please note that there are some print locations that have "blind" placement. These locations include the side seam and bottom hem areas.

Print Area - this term can be confusing so be careful not to use it in the wrong content when speaking to one of our customer service experts. The print area is the dimensions of the PRINTABLE area on a garment. Keep in mind that the print area might not take up the entire location.

Print Size is the exact measurements (width x height) of your art that is being printed in production.

screen size and placement on tshirt left chest

tshirt screen print placement back bottom hem

T-Shirt Sleeve Designs is an excellent way for your print or message to be memorable.

Often overlooked; custom t-shirts with sleeve printing provide a unique location for messaging.

With long sleeve t-shirt screen printing, this couldn't be more true.

Services, slogans, taglines, web addresses, even phone numbers are ideal.

For the best impact t-shirt design, 1 color print, bold font choice and simple messaging does the trick.

At Bolt, we follow this advice by adding our web address on the sleeve print design.

Our employees want to wear them. Spreading the word, is what a custom printed t-shirt should do every time.

Custom T-Shirts with Sleeve Printing are

BRAND-TASTIC!

How to Make Custom Embroidery Designs

Custom Screen Printing

What is Screen Printing?

Last Updated: 10-12-2021

What is Screen Printing?

Screen printing (also known as silk screening) is a popular printing process that pushes ink through a mesh screen to print your graphic design on a flat surface. Examples are screen print t-shirts and screen printed canvas tote bags.

Plastisol ink for screen printing is commonly used because it produces vibrant, bold colors that are difficult to replicate with other printing techniques such as digital printing. At Bolt Printing, we refer to screen printing as "traditional" printing.

Behind The Scenes at Bolt Printing

So what happens after we receive your high quality art files? Custom-made screens for the screen printing process begins. Here's the step-by-step process:

ART SEPARATION - the design is separated into layers by the number of print colors in the design.
CREATE A FILM POSITIVE - each layer is converted to black color and printed onto a transparent positive film for screen print.
PREPARE MESH SCREENS with photosensitive chemicals - This is one of the most important parts of what we do as printing experts here at Bolt Printing. The film is now placed onto a mesh screen, cleaned with a degreaser, and then coated with emulsion. The light-sensitive emulsion is exposed using UV light that burns the image onto the screen, thus creating a stencil. After the screen is exposed, it's rinsed off and fully dried.
SCREEN PRINTING - note that one screen is used for each color to be printed. For the colors to line up correctly, it's important that the screens line up (or registered). Ink is added to the screen and pushed through evenly with a squeegee onto the t-shirt. When there is a multi-colored screen, we often "flash" dry between layers of color to prevent bleeding.
BELT DRYER - the final step in the screen printing process is to place the printed t-shirts onto a conveyer belt that is heated at 380 degrees. This ensures the quality of the design for many years to come.