Once you have the blank, the logo decides how your piece reads — and how much it costs at your quantity. Here is the honest trade-off, method by method.
Embroidery
The classic. Thread on 380gsm+ fleece looks premium and survives 50+ washes. The catch is setup: each design needs its own digitised file and stabiliser plan, so per-unit cost falls steeply with quantity. On a 30-piece run it is the most expensive option; at 300 pieces it becomes the cheapest per logo. Avoid embroidery on thin performance jersey — the puckering shows.
Puff print
Raised 3D screen print, the streetwear staple. Reads like embroidery at a glance, costs like screen print at low quantity. Durability sits between flat print and embroidery; expect softening after ~20 washes. Needs a dedicated screen per colour.
DTG (direct-to-garment)
Inkjet on fabric. No setup, no minimum, photographic detail. Per-unit price is roughly flat, which makes it the winner under 50 pieces and for multi-design drops. On dark fleece it needs a white underbase, which slightly stiffens the print hand feel.
Sublimation / transfer
All-over colour only works on polyester fabric — sublimation ink bonds to synthetic fibres, not cotton. For cotton-heavy fleece, a cut-and-sew panel approach or printed transfer is the realistic path. Watch crack lines when transfers are applied over seams.
The 100-piece rule of thumb
Under ~60 pieces: DTG. Around 100: DTG or puff, price is close; pick by hand feel. Over 200: embroidery usually wins on unit economics and perceived value. Any method with a chest logo + back print combo, price the screens as one artwork package.
Send us your artwork and quantity on the quote form — we return a three-method cost comparison the same working day.
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