Is It Cheaper to Embroider or Print?

When it comes to customizing apparel or promotional items, two major decoration techniques come to mind: embroidery and screen printing. Both have their merits but when it’s time to choose, cost is often the deciding factor. Is it cheaper to embroider or print? The answer depends on several variables, from order size and design complexity to garment type and desired durability. This guide breaks down the key cost differences and helps you determine the most budget-friendly option for your needs.

Cost Comparison Overview

What Influences the Cost of Embroidery?

Embroidery pricing is typically determined by:

• Stitch count: The more stitches a design has, the longer it takes to embroider, which raises the cost.
  
  

• Number of colors: Although not as significant as in printing, multi-colored embroidery can slightly increase costs due to more thread changes.
  
  

• Setup fees: Digitizing your design into a stitch file involves a one-time setup fee.
  
  

• Garment preparation and hooping time: Each item must be hooped and aligned manually, which adds to labor.
  
  

Embroidery becomes more cost-efficient as quantity increases but for very large batches, it may still be pricier than printing.

What Affects Screen Printing Prices?

Screen printing is highly economical for large runs, but its cost structure includes:

• Color count: Each color requires a separate screen, increasing setup costs.
  
  

• Screen setup fee: While typically low, this fee applies per color and per design.
  
  

• Ink type: Specialty inks (metallic, puff, glow-in-the-dark) may cost extra.
  
  

• Print location and size: Larger prints or printing on multiple areas (front and back) increase pricing.
  
  

Unlike embroidery, screen printing costs are mainly driven by preparation and are best spread over larger volumes.

Key Factors to Consider

Quantity of Items

Printing is much more cost-effective when ordering in bulk. Once the screens are made, printing hundreds of shirts becomes relatively inexpensive per unit.

Embroidery, while still scalable, involves more time per piece. For small orders (under 24 items), embroidery may be more cost-effective depending on the design.

Complexity of Design

Embroidery handles simple logos, monograms, and minimal-detail graphics beautifully. However, for photo-realistic or intricate gradient designs, it falls short in terms of accuracy and efficiency.

Screen printing excels with complex or detailed visuals, especially if multiple colors or photo-quality images are involved. However, more complexity equals more screens, which means higher setup fees.

Garment Type and Material

Embroidery works best on thicker, more structured fabrics like polos, hats, jackets, and hoodies. It adds texture and elegance but may not suit lightweight materials like performance tees.

Screen printing is more versatile in terms of material compatibility and works well on cotton, blends, and synthetics. However, certain specialty materials may require adjusted inks or techniques, potentially increasing cost.

Pros and Cons of Embroidery

Durability and Appearance

Pros:

• Embroidery is extremely durable, resisting fading and cracking even after repeated washing.
  
  

• Offers a premium, raised texture that enhances brand perception.
  
  

• Excellent for corporate apparel and high-end retail items.
  
  

Cons:

• Limited in color gradients and fine detail.
  
  

• Can be uncomfortable on lightweight garments due to the added thickness.
  
  

• May cause puckering on stretchy or delicate fabrics if not stabilized correctly.
  
  

Price per Unit

Embroidery often has a higher base cost per unit due to longer production time and individualized setup. That said, its lack of dependency on color count makes it predictable in pricing once digitizing is complete, making it ideal for small quantities with minimal design changes.

Pros and Cons of Printing

Ideal for Large Batches

Pros:

• Extremely cost-effective for bulk orders.
  
  

• Handles large, full-color prints easily.
  
  

• Faster production time once the screens are ready.
  
  

Cons:

• Less durable than embroidery over time: prints may fade, crack, or peel.
  
  

• Setup costs can be high for multi-color or multi-placement designs.
  
  

• Designs can feel heavy or plasticky depending on the ink and fabric.
  
  

Limitations in Durability

While high-quality screen prints can last through many washes, they don’t match the lifespan of embroidery. Water-based inks tend to wear out faster, while plastisol inks offer better durability but add more texture to the garment.

Which Method Is Right for You?

When to Choose Embroidery

Embroidery is ideal when:

• You need a professional, high-end look (e.g., uniforms, business polos, caps).
  
  

• Your design is relatively simple and small (like logos or initials).
  
  

• Longevity and durability are a priority.
  
  

• You’re ordering small to medium quantities, especially when color count is low.
  
  

When to Choose Printing

Screen printing is your best choice when:

• You’re placing a large order and want to keep costs low.
  
  

• Your design includes complex or full-color graphics.
  
  

• You’re customizing lightweight or stretchable garments.
  
  

• Cost per unit is your biggest priority for a promotional event or giveaway.
  
  

Embroidery vs. Printing: Cost per Item Breakdown

When evaluating cost, it’s helpful to break it down to a per-item basis depending on order volume and design type:

In short, embroidery offers predictable pricing for small, simple runs, while screen printing is more cost-efficient at scale — especially when dealing with multi-color custom designs.

Printing methods compared: screen, transfer, and direct-to-garment

Screen printing isn’t the only method on the table. Businesses and designers now have access to multiple printing methods depending on budget, material, and visual complexity:

• Screen Printing: Best for bulk orders; vibrant colors and durability.
  
  

• Heat Transfer: Great for short runs and photo-quality images; quicker setup, but less long-lasting.
  
  

• Direct-to-Garment (DTG): Ideal for complex artwork on t-shirts; no setup required, but slower for large orders.
  
  

Each method has distinct pros and cons. For example, heat transfer is fast and low-cost upfront, but not ideal for workwear or long-term use. Understanding these nuances helps select the right technique for your shirt, long sleeve, or custom apparel needs.

Use case spotlight: customizing workwear and safety apparel

If you're outfitting a team or workforce, embroidery offers standout benefits. For instance:

• Polo shirts with left-chest logos provide a clean, professional appearance ideal for client-facing roles.
  
  

• Sleeve embroidery can display certifications or departmental names for safety teams.
  
  

• Embroidered workwear withstands repeated washing and rough usage, essential for trade and industrial settings.
  
  

Though screen printing may seem more affordable, the long-term durability of embroidery often yields a better return on investment for uniforms and gear.

Selling custom products: which method yields better value?

If you’re planning to sell custom-designed products (like t-shirts, hoodies, accessories, or polo shirts) both methods have pros depending on your niche:

• Embroidery elevates the perceived value of premium products, especially in fashion, corporate gifting, or boutique shops.
  
  

• Screen printing works best for mass-market designs, seasonal promos, and merchandise with trendy graphics.
  
  

Embroidery may come at a higher upfront embroidery cost, but customers often associate it with quality craftsmanship, allowing higher price points and margins. Conversely, screen printed designs are ideal for quick-turnaround, high-volume sales where price competitiveness is key.

The fabric factor: matching technique to material

Not all decoration methods suit every fabric type. The base material plays a major role in determining both cost and final look:

• Cotton and cotton blends are compatible with all printing methods and embroidery.
  
  

• Stretchy or athletic fabrics (like performance tees and women's fitted wear) require careful stabilizing if embroidered, or may benefit from transfer printing instead.
  
  

• Thicker fabrics like canvas or denim showcase embroidery beautifully but may absorb more ink in printing, affecting clarity.
  
  

When selecting between embroidery and printing, always align the technique with fabric properties to avoid warped designs, bleed-through, or discomfort.

Conclusion

So, is embroidery cheaper than printing? Not necessarily. For small orders with simple designs, embroidery may be more economical. But if you're producing a high-volume run or need vibrant, multi-color graphics, screen printing wins the price battle.

Ultimately, the right choice depends on your goals, your design, and the number of garments you're customizing. Consider both the short-term cost and long-term value (especially in terms of durability and appearance) before you decide.