Screen Printing vs Embroidery: Which Is Better for Custom Workwear?

When we talk about branding uniforms or staff apparel, the debate between screen printing and embroidery has been going on for decades. Both methods deliver professional results, but they suit different needs, budgets, and types of workwear.

Choosing the right one isn’t just about appearance, it’s about how your logo performs in the field, how long it lasts, and how it represents your business day in and day out.

In this guide, we’ll unpack everything you need to know about screen printing vs embroidery for custom workwear, including pros, cons, durability, cost, and what works best for different industries.

What Is Screen Printing?

Screen printing involves pushing ink through a fine mesh stencil onto fabric. Each colour in the design requires a separate screen, which makes it ideal for bold logos, solid shapes, and large-format designs.

The result? A smooth, durable print that sits directly on the fabric.

What Is Embroidery?

Embroidery uses high-speed machines to stitch your design with thread directly into the garment. It creates a raised, textured look that adds sophistication and durability.

The result? A professional, high-end finish that feels timeless.

1. Appearance and Finish

Screen Printing Look

Screen printing gives a flat, vibrant finish, excellent for colourful logos or larger graphic designs. You can choose from matte, gloss, or metallic inks, and achieve precise colour matching with Pantone codes.

Screen prints appear smooth and bold, ideal for visual impact on back panels or chest areas.

Embroidery Look

Embroidery delivers texture and dimension. The threads add depth, catching light and giving a premium touch to the garment. It’s ideal for company logos, monograms, and small-to-medium graphics on polos, jackets, or caps.

Verdict:

• Screen printing: Great for bold, colourful visuals.
• Embroidery: Ideal for elegant, professional branding.

2. Durability

Screen Printing Durability

Screen printing can last for years if cared for properly. High-quality inks bond strongly to fabric fibres, but over time, especially after heavy washing, prints may crack or fade slightly.

It’s more suitable for cotton, cotton-blend, and polyester fabrics.

Embroidery Durability

Embroidery outlasts almost every other decoration method. The stitched threads are physically woven into the garment, making them resistant to fading, washing, and harsh conditions.

It’s perfect for heavy-duty workwear that goes through constant wear, washing, or exposure to the outdoors.

Verdict:

• Embroidery wins for durability and long-term use.
• Screen printing is still strong but better suited to lighter uniforms and promotional wear.

3. Cost and Order Size

Screen Printing Costs

Screen printing becomes more cost-effective as order size increases because setup costs (creating screens for each colour) are shared across the batch.

• Ideal for bulk orders.
• Best for simple designs with few colours.

However, small orders with multi-colour logos can be expensive due to setup time.

Embroidery Costs

Embroidery pricing depends on stitch count, not colour count. Complex logos with high detail take longer to stitch, increasing the cost per unit.

• Great for small to medium orders.
• Cost remains steady regardless of logo colours.

Verdict:

• Screen printing: More cost-effective for large runs.
• Embroidery: Better value for small quantities or multi-colour logos.

4. Fabric Compatibility

Screen Printing Works Best On:

• Cotton and cotton blends.
• Polyester (with correct ink treatment).
• Smooth, flat fabrics.

Avoid heavily textured materials; ink can break on rough surfaces like fleece or heavy canvas.

Embroidery Works Best On:

• Polos, jackets, caps, and thicker garments.
• Fleece, drill, and denim.
• Any material that can support needle tension.

Thin fabrics may pucker under stitching, so embroidery isn’t ideal for lightweight tees.

Verdict:

• Screen printing: Lightweight fabrics.
• Embroidery: Heavier, structured fabrics.

5. Design Detail and Colour Range

Screen Printing

Allows full creative freedom. You can use gradients, large fills, or vibrant colour schemes. Speciality inks such as metallic, neon, puff, or glow-in-the-dark are all options.

Because each colour needs a separate screen, complex multi-colour prints cost more but look striking.

Embroidery

Embroidery is more limited by the thickness of the thread. Small text, fine details, and gradients can’t always be replicated. You can use up to 15 thread colours in one design, but clean, simple logos perform best.

Verdict:

• Screen printing: Best for creative and detailed artwork.
• Embroidery: Best for bold, simple logos.

6. Professional Appeal

If your business needs polished uniforms, think hospitality, corporate teams, or client-facing staff; presentation is everything.

Screen Printing Appeal

Modern and casual. It suits relaxed workplaces or industries where a bold logo helps the brand stand out, like gyms, retail stores, or events.

Embroidery Appeal

Elegant and high-end. The tactile quality of thread adds a touch of prestige to uniforms and outerwear. Perfect for banks, restaurants, schools, and medical practices.

Verdict:

• Screen printing: Energetic and youthful.
• Embroidery: Professional and premium.

7. Maintenance and Longevity

Screen Printing Care

Machine-wash inside-out on cold. Avoid harsh detergents and tumble dryers to keep prints bright. Over time, the print layer may soften or fade slightly.

Embroidery Care

Embroidery holds strong through repeated washing. Threads may fray slightly if exposed to sharp edges or rough surfaces, but colours stay vivid for years.

Verdict:

Embroidery takes the lead in long-term resilience. Screen prints still hold up well with proper care, especially when high-quality inks are used.

8. Environmental Considerations

Today’s buyers care about sustainability.

Screen Printing

Eco-friendly water-based inks are now available, significantly reducing solvent use and waste. However, screen setup generates more materials (screens, emulsions, inks).

Embroidery

Embroidery produces minimal waste. Some brands, such as AS Colour and Biz Collection, pair embroidery with sustainable garments for a lower environmental footprint.

Verdict:

Both can be eco-friendly, but embroidery typically produces less waste overall.

9. Which Method Is Best for Each Industry?

10. Combining Both Garment Decoration Methods

Sometimes, the best solution is to use both.

For example:

• Screen print the large back logo on a work tee.
• Embroider the small chest logo for a premium touch.

This approach gives flexibility, visual impact and texture where it matters most.

11. Cost Comparison Example

(Prices vary based on quantity, design complexity, and garment brand.)

12. Choosing the Right Option for Your Workwear

Here’s a simple way to decide:

Choose Screen Printing If You Want:

• Large, bold designs that stand out.
• Cost-effective branding for events or promotions.
• Breathable, lightweight uniforms.

Choose Embroidery If You Want:

• Long-lasting logos for everyday uniforms.
• A polished, professional look.
• Durability against washing and wear.

Or Combine Both:

• Screen print for visibility.
• Embroider for prestige.

13. Workwear Fabrics and How Decoration Reacts

Cotton and Cotton Blends

Best for screen printing, inks bond easily and colours appear vibrant.

Polyester and Synthetic Blends

Embroidery performs better here since polyester can resist the heat used in printing.

Heavy Fabrics (Fleece, Canvas, Jackets)

Embroidery produces cleaner, more durable results.

Light Fabrics (T-Shirts, Activewear)

Screen printing keeps garments breathable and flexible.

14. Common Mistakes to Avoid

• Using thin fabrics for embroidery: Causes puckering or tension issues.
• Over-detailed logos in embroidery: Threads can blur fine lines.
• Ignoring garment prep: Always pre-wash cotton garments before printing.
• Using plastisol inks on high-stretch fabrics: Can cause cracking.
• Not digitising embroidery files properly: Leads to uneven stitching.

T-Shirt Plus handles all these technicalities, ensuring your logo looks spot-on every time.

15. The Verdict: Screen Printing vs Embroidery

If your focus is visibility and creativity, choose screen printing.
If you want durability and prestige, go with embroidery.

Many Australian businesses mix both, embroidered polos for daily wear and printed tees for events or promotions.

16. Why T-Shirt Plus Is the Best Choice for Custom Workwear

T-Shirt Plus is a pro in both screen printing and embroidery under one roof. Our team works with Australia’s leading apparel brands, including AS Colour, JB’s Wear, Biz Collection, and Syzmik, ensuring every piece looks sharp, feels comfortable, and lasts.

Here’s what you can expect:

• Expert advice on the right decoration for your fabric and design.
• State-of-the-art equipment for crisp printing and precise stitching.
• Fast turnarounds and bulk-order pricing.
• Local production for Aussie businesses.

Whether it’s polos for the office, safety gear for worksites, or printed tees for your next campaign, we’ll help you get it right from the start.

In the end, there’s no one-size-fits-all answer. Both screen printing and embroidery have unique strengths.

If you want bold, affordable branding on lightweight workwear, screen printing is your best bet.
If you want professional, long-lasting logos that elevate your brand, embroidery wins every time.

T-Shirt Plus will help you choose the method that fits your business, budget, and brand personality, and make sure your custom workwear looks top-notch from the first stitch to the last print.