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 :)

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.

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

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.

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.

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.

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.

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.

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.

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.

Styling and design of logos that look best embroidered:

Bold and simplistic imagery in distinct colors.

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.

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.

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:

1. ART SEPARATION - the design is separated into layers by the number of print colors in the design.

2. CREATE A FILM POSITIVE - each layer is converted to black color and printed onto a transparent positive film for screen print.

3. 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.
   

4. 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. 

5. 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.