One of the challenges we encounter when Embroidering small text or Artwork, for example, 1" wide or less, is that the smaller the design, the more difficult it becomes to retain perfect resolution and sharpness.

When this happens, we remedy it by using the appropriately weighted Thread and corresponding Needle size. For example, A Thread weight of 60 is 25% less thicker than an industry standard 40-weight Thread. So, when a 60-weight Thread is required, a thinner Needle size will subsequently need to be implemented in conjunction. In addition to closely scrutinizing the Embroidery Digitizing process step by step ensuring a clean finish.

Text characters embroidered at 1" or 2" in width and greater, would yield a cleaner finish by default regardless of the Needle size or Thread weight. This is due to the stitch proximity, and the Needle having enough room to complete every detail and in turn yield a clean and robust finish. For a less straightforward production like custom designed Artwork, we seek to find a perfect balance between the Fabric, Needles, Thread, and Stabilizers, at the same time taking into account the type of composition being Embroidered, be it a Logo or Lettering.

As a general rule, we keep small text at no less than 6mm if possible. Sometimes, a character will need to be scaled down to 4mm or even 3mm, this of course depends on the Typeface being Embroidered. These measurements are extremely small which is when we would implement a smaller needle so as not to puncture the fabric when attempting to stitch the openings of a Typeface. For example, the letters Q, P, or O.

Take a look at the two examples shown below; a small Embroidered Polo by Ralph Lauren Horse alongside the same Horse embroidered at a larger scale. Upon comparing the two examples, you will come to realize details in the larger Horse that do not exist in the smaller Horse. For example, if you take notice of the Straps surrounding the bigger Horse' Legs, including the details in the Riders Kneed Pads, these details are not seen in the example of the smaller Horse.

PROPERTY OF RALPH LAUREN CORPORATION.

Generally speaking, in Embroidery, the smaller your Artwork or Text, the more resolution you lose. The larger your overall design scale, the more resolution and details are retained. (The same can be said for Screen Printing, however, the effects of scale are more noticeable when Embroidering versus Screen Printing)