Embroidery vs. Screen Printing: What’s Best for Your Apparel Project?

When you’re planning a custom apparel project—whether for your business, event, team, or organization—choosing the right decoration method is key. Two of the most popular options are screen printing and embroidery, but they each come with unique benefits.

At Pacific Printing in Ketchikan, we offer both services because we know that one size never fits all. Let’s break down the differences to help you decide what’s best for your next project.

What is Screen Printing?

Screen printing is the process of pressing ink through a mesh screen onto fabric, one color at a time. It’s the go-to method for printing bold, vibrant designs—especially on t-shirts, hoodies, and athletic wear.

Best for:

• T-shirts
• Sweatshirts & hoodies
• Team uniforms
• Event or promotional shirts
• Large quantity orders

Pros:

• Cost-effective for large runs
• Vibrant colors
• Great for bold, graphic designs
• Works well on cotton and cotton blends

Cons:

• Less ideal for small detail or gradients
• Less durable on high-wear areas
• Not ideal for small quantities

What is Embroidery?

Embroidery involves stitching thread directly into the fabric to create a design. It’s known for its durability, polished look, and premium feel—often used on hats, polos, jackets, and workwear.

Best for:

• Polo shirts
• Hats and beanies
• Jackets and outerwear
• Uniforms and workwear
• Small quantity or specialty orders

Pros:

• Long-lasting and durable
• Professional, upscale appearance
• Adds texture and dimension
• Great for logos

Cons:

• Typically, more expensive per piece
• Not suited for detailed or small text
• Limited color blending

How to Choose: Ask Yourself These Questions

1. How many items do I need?
   Screen printing becomes more cost-effective as quantity increases, while embroidery pricing remains more consistent regardless of the number of items.
2. What kind of fabric am I printing on?
   Screen printing works great on smooth cotton or poly blends. Embroidery works best on heavier fabrics like jackets, hats, or polo shirts.
3. Is this a promotional or professional item?
   If you’re handing out branded shirts at an event, screen printing is likely your best bet. But for employee uniforms or formal branded gear, embroidery adds a polished touch.
4. What’s my budget?
   For large orders with colorful designs, screen printing is the budget-friendly winner. For smaller runs or high-end appearance, embroidery is worth the investment.

The Hybrid Option: Mix and Match

Some clients choose screen printing for t-shirts and embroidery for hats or polos—and that’s perfectly fine! At Pacific Printing, we help you build custom apparel packages that include both.

Let’s say you’re running a fishing charter in Southeast Alaska. You might:

• Screen print bold logos on shirts for your crew and customers
• Embroider caps and jackets with a smaller version of your logo for staff

It’s about using the right method for the right item.

Our Local Expertise Matters

Here in Ketchikan, your gear has to hold up in rain, wind, and wear. We help you select durable, comfortable fabrics and apply the method that’s going to look good for the long haul.

We’ll show you samples in person, walk you through color matching, and make sure you know exactly what you’re getting—something those big-box online printers just can’t do.

Ready to get started?
Let’s build an apparel package that works for your brand, your budget, and your audience.

Contact Us today to get started!