Creating the perfect embroidery file

Learn about the most common issues with embroidery files and how to avoid them

1. Flat embroidery
A technique where stitches are embroidered flat on the surface.

 

2. Thread colors
All available colors.

 

3. Tatami fill
Rows of run stitches used to fill large areas.

4. 3D Puff embroidery
A technique where the embroidery is raised, used mostly for big shapes.

 

5. Satin stitch outline
A long, straight embroidery stitch used to outline objects or to cap a 3D Puff design.

 

6. Run stitch
A single line stitch used for small details.

What to keep in mind

Follow the guidelines
Adhere strictly to the embroidery guidelines to prevent any problems with your designs. Detailed instructions for each embroidery product can be found on the product's page.

Follow the guidelines
When modifying embroidery files, make sure to work within the specified embroidery area dimensions. Our templates will help keep your designs within the allowable maximum area.

What is digitization?

Digitization is the process of transforming your design into a format compatible with embroidery machines. Each type of embroidery requires a unique digitized file. For more information on digitization fees, click here.

Most common issues with standard color embroidery

  • Text too small, lines too thin

  • Distressed/textured graphics

  • Negative space objects

  • Gradients

  • Solid backgrounds

  • Photographic images

  • 3D puff

  • Side embroidery

Text too small, lines too thin

 

To ensure readability, avoid using very small letters in your embroidery designs. Maintain a minimum text height of 0.25 inches and a thickness of at least 0.05 inches. The minimum recommended line thickness for a regular satin stitch is 0.05 inches. For thinner lines, a run stitch (a single line of stitches) will be used. In Adobe Illustrator, you can measure the text using the measuring tool or by converting the font point size to inches: go to File > Preferences > Units > General > Inches. A height of 0.25 inches is roughly equivalent to 36pt, ensuring adequate letter thickness, though this may vary depending on the font. We recommend using simple fonts like Arial or Helvetica.

Distressed/textured graphics

 

When using distressed or textured graphics, fine details may be lost in the embroidery process depending on the texture's size. For these designs, only flat embroidery will be possible, and extremely thin elements will likely be executed with a run stitch.

Negative space objects

 

Negative spaces in the artwork allow the hat fabric to show through the design, which can lead to problems. Don't confuse this with a transparent background, which is acceptable. To prevent issues, fill the negative spaces with another color.

Gradients

 

In standard embroidery, only solid shapes and colors can be used. Gradients are not feasible because smooth color transitions cannot be achieved. You'll need to replace gradients with solid colors. If your design requires gradients, opt for unlimited color embroidery instead.

Solid backgrounds

 

Graphics that occupy a significant portion of the embroidery area will likely surpass the 15,000-stitch limit. To avoid this, ensure all backgrounds are removed from your files. If you wish to retain the background, the graphic size will need to be reduced by up to 50%. Embroidering photographic images directly is not feasible; they must be redesigned using solid shapes and colors.

Photographic images

 

Photographic images cannot be directly embroidered. Instead, they need to be redesigned using solid shapes and colors.

3D puff

 

Utilize bold shapes and text for 3D puff embroidery. Graphics that do not meet the minimum thickness requirements cannot be embroidered in 3D puff. Additionally, certain fonts, such as calligraphy, are not suitable for this technique.

Side embroidery

 

The side embroidery area is more limited compared to the front. To ensure a high-quality result, keep your text to a maximum of 10 characters per line.

Most common issues with unlimited color embroidery

  • Too small, too many details

  • Small details

  • Neon and metallic colors

  • Garment weight

  • Gradients

  • Hats

  • Solid backgrounds

  • Negative space objects

Too small, too many details

 

Avoid using graphics with details smaller than 0.86″ (20 mm) in width as they can lead to color discrepancies and embroidery stiffness.

 

To ensure smooth color transitions between two solid colors, use large, simple, and filled shapes rather than graphics with numerous small parts covering a large area.

Small details

 

Even if a graphic is wider than 0.86″ (20mm), small details and abrupt color changes can cause slight color shifts.

Neon and metallic colors

 

The white recycled polyester thread used for unlimited color embroidery is dyed with CMYK inks, which cannot achieve bright neon or metallic colors. For such colors, standard embroidery might be a better option if the desired thread color is available.

Garment weight

 

Small details in graphics can cause lightweight garments to pucker. To incorporate color changes for hard shifts, at least 11.8″ (300 mm) of thread must be hidden in each design section, making graphics with smaller details stiffer.

Gradients

 

Avoid using small or short gradients in designs. Gradients look best when stitches flow naturally, mimicking handwritten text. Block letter fonts may show sharp color transitions, so slow or smooth gradients are recommended.

 

For good results with serif fonts, choose several letters for the transition. Otherwise, letters with two serifs will show choppy color changes.

Hats

 

Avoid placing designs on hat seams to prevent color misalignment. A standard center seam is 0.4″–0.6″ (10-15 mm) wide, so adjust your design to have ample space around the seam.

Solid backgrounds

 

To achieve a cleaner and smoother look, set an outline around embroidery designs with solid shapes.

Negative space objects

 

Negative spaces in artwork, where the fabric shows through, can lead to uneven edges and deformed designs due to embroidery shifting, pinching, and puckering. To avoid these issues:

  • Fill the negative spaces with color.
  • Avoid using small or short gradients.

Additional important information about embroidery

Stitches and Designs 

Our digitizers decide what stitches will be best for each design. It's important to adhere to the provided guidelines, as the chosen stitch type will ultimately depend on the specifics of your graphic.

 

Similar Graphic, Different Outcome 

Be aware that submitting a new graphic that appears similar to one you've previously uploaded may not result in the same digitization. This variation occurs because different digitizers manually process the files, and each may interpret and digitize the graphic differently.

 

Adjustment Fees

The stitch density and direction vary between hat and apparel embroidery. If you want to use hat files for shirts or vice versa, adjustments are necessary and cost $2.95 per file. Note that 3D puff embroidery is not available for apparel, so any 3D puff hat files you have will need to be re-digitized from scratch for use on apparel.

 

Embroidery Backing 

Embroidery backing is an additional layer of fabric placed inside the product and embroidered along with the design. This backing stabilizes the stitching and supports the embroidery, ensuring that your designs look great and have a long lifespan.