The decoration method matters as much as the garment itself — it is the difference between a branded uniform that holds the company image for 18 months under industrial laundry, and a print that fades to ghost-grey by month four. Each method has a clear use case.
Embroidery — the workwear default
- Durability: Outlasts the garment under industrial laundry (200+ cycles)
- MOQ impact: None — digitization is one-time cost (~$30-60), per-garment cost depends on stitch count
- Best for: Chest logos (chest-position corporate logo, 4,000-12,000 stitches typical), name patches, premium feel
- Limitations: Detail capped by stitch density; very fine type below ~6mm becomes mushy; max ~12 colors before complexity overhead
- Cost band: $0.40-$1.20 per logo on standard chest position (depends on stitch count)
Screen print — for backs and volume
- Durability: 50-100 industrial wash cycles before significant fade
- MOQ impact: Screen setup cost per color (~$25-40), so cost-effective at 50+ pcs per color
- Best for: Large back-panel logos, t-shirts, hoodies, multi-piece volume orders, multi-color graphics up to 6 colors
- Limitations: Stiff hand-feel on heavier ink layers; not suitable for hi-vis fluorescent fabric (cures change brightness); won't work on FR garments unless using FR-certified ink
- Cost band: $0.20-$0.60 per logo per color
Heat transfer vinyl (HTV) — for individual names
- Durability: 30-50 wash cycles before edges begin to lift
- MOQ impact: No setup — true 1-pc minimum (ideal for individual name customization)
- Best for: Individual name patches, low-volume short-run customization, hi-vis reflective transfer logos
- Limitations: Lower lifecycle than embroidery; edges peel under aggressive industrial laundry
- Cost band: $0.50-$1.50 per name patch including production
Sublimation — for full-color polyester
- Durability: Effectively permanent (dye is embedded in fiber, not printed on surface)
- MOQ impact: Sublimation paper roll cost, so per-garment cost-effective at 200+ pcs
- Best for: All-over photographic prints, team-color polos, gradient designs, full-color graphic workwear
- Limitations: Polyester only (or > 65% poly blend); can't sublimate cotton; can't sublimate dark fabrics
- Cost band: $0.80-$2.50 per all-over print depending on coverage
- Deep dive: see our full sublimation printing guide for exactly when dye-sub beats embroidery and screen print
Recommendation matrix by use case
| Use case | Recommended primary method | Common combination |
|---|---|---|
| Construction firm logo on hi-vis polo | Embroidered chest + back-panel screen print | Embroidery + screen print |
| Hotel front-desk staff uniform | Embroidered crest only (premium feel) | Embroidery only |
| Warehouse polo with crew name | Embroidered chest logo + HTV individual name | Embroidery + HTV |
| Promotional event t-shirt (1,000+ pcs) | Screen-printed front + screen-printed back | Screen print only |
| FR welder coverall logo | Embroidered with FR-rated thread | Embroidery (FR thread) |
| Athletic team polo with team graphics | Sublimation print all-over | Sublimation only |
Sourcing a branded workwear program?
Send us your logo and the use case — we will recommend the best decoration method, quote with mockups and indicative pricing within three business days.
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