Two of the most popular ways to decorate custom apparel are screen printing and embroidery. Both produce professional results, but they work differently and suit different situations. Understanding the distinction will save you money and get you a better end product.

What Is Screen Printing?

Screen printing pushes ink directly through a mesh stencil onto the fabric. Each colour in your design requires a separate screen, which is why setup costs are higher upfront but the per-unit cost drops significantly at volume.

It produces bold, vibrant colours and works best on flat surfaces like T-shirts, hoodies, and tote bags. The print sits on top of the fabric, giving you sharp, clean results with large areas of solid colour.

What Is Embroidery?

Embroidery stitches your design directly into the fabric using thread. The result is a raised, textured look that feels premium and lasts virtually forever. Embroidered logos do not crack, fade, or peel the way printed ones can over time.

It works on almost any garment but is especially well-suited to polo shirts, hats, jackets, and uniforms where a professional, elevated appearance matters.

When Should You Choose Screen Printing?

You have a large order (24+ pieces) and want the best price per unit
Your design has large areas of solid colour or bold graphics
You are printing on soft, flat garments like T-shirts or hoodies
You want a print that covers a large area of the garment
Your design has photographic detail or gradients (with specialty printing techniques)

When Should You Choose Embroidery?

You want a premium, professional look for uniforms or corporate wear
You are decorating hats, polo shirts, or structured garments
Your logo is relatively compact with clean lines
Durability is the top priority — embroidery outlasts almost every other decoration method
You have a smaller quantity order and upfront screen setup costs do not make sense

What about Vinyl?

Vinyl (heat transfer) is a third option that sits between screen printing and embroidery. It is ideal for small runs, names and numbers, or designs with many colours that would require expensive multi-screen setups. At Sandstar we often recommend vinyl for orders under 12 pieces or for designs with complex colour gradients. Visit our services page to learn more about all our apparel decoration options.

How Do the Costs Compare?

Screen printing has a higher setup cost (creating the screens) but a lower per-unit cost at volume. The sweet spot is typically 24 pieces or more. Below that, vinyl or embroidery will often work out cheaper.

Embroidery is priced by stitch count, so larger or more complex designs cost more. A standard left-chest logo runs very affordably, but a full-back design will cost more. The payoff is longevity.

Still Not Sure? Ask Us.

Bring your design, tell us your quantity, and we will recommend the right method for your order and budget. We have been decorating apparel in Saskatoon for over 25 years and will give you a straight answer.

Also worth reading: How to Prepare Your Files for Printing and Why Custom Signage Is a Smart Investment for Saskatoon Businesses.

Screen Printing vs. Embroidery: Which Is Right for Your Order?