Embroidery or Printing for Polo Shirts and Caps: How to Choose
Comparing embroidery, screen printing and DTF for polo shirts and caps — prices, minimum quantities, turnaround times and which logo type suits each technology.
The choice between embroidery and printing is usually simple: for polo shirts and caps with a small logo on the chest or cap front, embroidery is more practical (roughly 4.00 to 6.00 EUR per placement, excl. VAT), while large, multicoloured images and photos call for printing (screen printing from roughly 1.50 EUR at high volumes, DTF from 4.00 EUR). Embroidery withstands 50+ washes without changing, screen printing roughly 30-50 washes with proper care. In both cases, turnaround is 5-10 business days after artwork approval, depending on quantity.
Quick answer: what to choose when
- Embroidery — polo shirts, caps, sweatshirts, jackets, uniforms; logo up to roughly 8 x 8 cm; 1-6 colours; quantities from 1 piece.
- Screen printing — large runs (from 50-100 pcs), simple graphics with 1-3 colours, T-shirts and cotton polos.
- DTF (film transfer) — small quantities, multicoloured and gradient logos, garments of different colours in one order.
- Sublimation — only white or light-coloured polyester items, sports polos, all-over patterns.
Embroidery: what it gives you and what it doesn't solve
Embroidery is thread stitched into the fabric, so it never peels, cracks or fades. On a polo shirt with dense piqué fabric, embroidery looks finished and holds up well to frequent washing — which is why restaurants, sports clubs and municipal staff choose it when the garment needs washing 2-3 times a week.
There are two limitations. First, a detail threshold: text smaller than 4-5 mm and thin 0.3 mm letter elements tend to blur together in embroidery. Second, embroidery adds thickness to the garment, so on very thin knits (140 g/m² and below) the area may pucker slightly; this is addressed with a stabilising backing.
Before the first job, the logo needs to be converted in embroidery software (digitising) — a one-off fee of roughly 15-30 EUR, which stays on file and isn't charged again for future orders. The stitch count for a typical chest logo is 4,000-10,000, which directly affects the price.
Printing: screen printing, DTF and sublimation
Screen printing becomes cost-effective from 50-100 pieces in the same design. Each colour needs a screen (roughly 15-25 EUR per colour), but after that the per-unit cost is low. The ink sits in a thin layer, so large areas on a shirt stay flexible and lightweight.
DTF is the solution for small runs — 1-50 pieces, many colours, photos, complex outlines. No screens are needed, so setup costs are close to zero. On a polo shirt, DTF holds up well on smooth areas; we don't recommend it on coarse-textured fabric or stretchy seams.
Sublimation only works on light-coloured polyester and dyes the fibre rather than forming a layer — the print isn't felt by touch, but this method can't print on black or coloured cotton polos. For a more detailed overview of garment printing options, see the garment printing page.
Price and turnaround comparison
Prices are indicative, excl. VAT, per one printing/embroidery placement; the price of the garment or cap itself is not included.
| Technology | Suited for | Min. quantity | Price at 10-20 pcs | Price at 100+ pcs | One-off costs | Turnaround |
|---|---|---|---|---|---|---|
| Embroidery (chest logo) | polos, sweatshirts, jackets | 1 | from 6.00 EUR | from 4.00 EUR | digitising 15-30 EUR | 5-10 business days |
| Embroidery on a cap | caps | 1 | from 6.00 EUR | from 4.50 EUR | digitising 15-30 EUR | 5-10 business days |
| Screen printing, 1 colour | T-shirts, cotton polos | 30 | from 3.50 EUR | from 1.50 EUR | screen 15-25 EUR/colour | 5-10 business days |
| DTF | small runs, multicolour | 1 | from 6.00 EUR | from 4.00 EUR | none | 5-10 business days |
| Sublimation | light-coloured polyester | 1 | from 5.00 EUR | from 3.00 EUR | none | 5-10 business days |
The exact price depends on quantity, print size, number of colours or stitches, and garment type. Rush jobs are available by separate agreement.
Caps: why embroidery wins in practice
The front of a cap is curved and often has a foam or stiff insert, so flat printing methods can't cover it evenly. Embroidery on a cap is done on a special frame, and the logo keeps its shape even after years of wear.
Practical tips for cap embroidery:
- optimal logo width on the cap front — 5-9 cm, height up to 5 cm;
- text at least 5 mm tall, otherwise the letters fill in;
- 3D (puff) embroidery looks great on caps with a stiff front;
- for the sides and the closure strap, we recommend smaller embroidery — up to 4 cm wide.
You can browse styles and materials on the caps page, and other promotional products with your logo in the promotional products section.
Files: what to send with your order
Both technologies require vector artwork: .ai, .eps or .pdf with CMYK colours and text converted to outlines. If you only have a PNG or JPG, the logo needs to be redrawn — this usually takes one business day.
It also helps to specify your corporate colours as Pantone codes: for embroidery, we choose thread based on the closest Pantone shade, and the same logic applies to screen printing ink mixing. Before a large run, we prepare one sample on request.
How to decide in 30 seconds
- How many pieces? Up to 30 — embroidery or DTF. From 100 with simple graphics — screen printing.
- How big is the logo? Up to 10 cm — embroidery. Full back of the shirt — printing.
- How many colours, and are there gradients? Gradients and photos — only DTF or sublimation.
- How often will it be washed? For workwear washed daily, choose embroidery.
- What fabric? Coarse texture or stretchy sports material — embroidery or sublimation.
Frequently asked questions
Is embroidery more expensive than printing?
At small quantities, the difference is minor — both embroidery and DTF start at roughly 6.00 EUR per placement. At large volumes, screen printing becomes significantly cheaper (from 1.50 EUR), since the embroidery price is determined by the stitch count, which doesn't change.
Can fine text be embroidered on a cap?
The safe limit is 5 mm letter height. Smaller text, slogans and web addresses are better suited to DTF printing, or the logo size should be increased.
How long does an order take?
The standard turnaround is 5-10 business days after artwork approval — depending on the technology, quantity and garment availability. Rush jobs are available by separate agreement.
Can both technologies be combined in one order?
Yes, and it's often the best option: an embroidered logo on the chest and a larger printed image on the back or sleeve. We calculate each placement separately.
Do you work with a single piece?
Yes. Embroidery and DTF can be done from 1 piece; screen printing only makes sense from around 30 pieces due to screen costs.
Send us your logo and the quantity you need to info@attaprint.lv or message us on WhatsApp at +371 25776699 — we'll prepare a quote with price, turnaround and recommended technology within one business day. You can browse our other printing services in the shop section.
FAQ
Is embroidery more expensive than printing?
At small quantities, the difference is minor — embroidery from 4.00 EUR, DTF from 3.00 EUR per placement (excl. VAT). At large volumes, screen printing becomes significantly cheaper (from 0.60 EUR), since the embroidery price is determined by the stitch count, which doesn't change.
Can fine text be embroidered on a cap?
The safe limit is 5 mm letter height. Smaller text, slogans and web addresses are better suited to DTF printing, or the logo size should be increased.
How long does an order take?
The standard turnaround is 3-10 business days: DTF jobs 3-6 days, embroidery and screen printing 5-10 days depending on quantity and garment availability. Rush jobs are available by agreement.
Can both technologies be combined in one order?
Yes. Often the best option is an embroidered logo on the chest and a larger printed image on the back or sleeve. Each print placement is calculated separately.
Do you work with a single piece?
Yes. Embroidery and DTF can be done from 1 piece; screen printing only makes sense from around 30 pieces due to screen costs.
