Creating an Embroidered Design
Elements of a High Quality Embroidery Design
Generally speaking, there are two types of threads used for embroidered designs, Polyester and Rayon. Rayon produces the best looking embroidered designs, however it can be prone to breakage during stitching and it is slightly less durable than Polyester. Polyester is quite durable, however it does not always produce great looking designs on all types of fabrics. Many people choose Rayon over Polyester thread because it looks great on all fabric types.
Thread Color
Choosing the right thread color is probably the most important thing you will need to think about. You need to be concerned with how the colors in your design will look with the color of the garment that you choose. In general, less contrast between the garment color and embroidery color is best since this tends to hide imperfections in the stitching. The threads in fabric form a "grid" with series of microscopic openings. The thread that makes up the embroidered design is passed through these small openings as the design is stitched. Fabrics that have relatively large openings (knits) tend to cause the edges of the design to be slightly imperfect. An experienced embroidery designer can optimize the fill stitch so that your design will look great on a variery of fabrics.
Fill Stitch
Filled in areas of the design are made up of tiny stitches arranged in a pattern. If there are too many stitches, they will tend to pull on the fabric and create small gaps in the fabric around the outside of the design. To few stitches and the fabric will show through the design. To make matters worse some fabric types are more sensitive to stitch fill than others. For example, a design may look great when stitched on a woven baseball cap, however when stitched on a polo shirt the results may be disappointing. An experienced designer will create a design that provides an optimal stitch fill for a variety of fabrics.
Backing Materials
Backing materials provide support and structure to an embroidered design and are critical to a long lasting design. A sheet of backing material is placed behind the area where the design will be applied. The design is then stitched through the fabric and the backing material. There are two types of backing material "Tearaway" and "Cutaway". As the name suggests, tearaway backing can be torn off without tools after the design is stitched. Cutaway backing must be cut around the design using scissors after the design is stitched. It is very important to match the backing to the type of fabric being embroidered. Tearaway backing is typically used with woven fabric such as dress shirts. Cutaway backing is used on knit fabrics. As you would probably guess, tearaway backing is the easiest for the embroidery shop to use since it is easy to remove. Some less reputable embroidery companies use only tearaway backing or worse no backing at all! A quality embroidery job should be using backing appropriate for the fabric.
Topping
Some fabrics such as fleece, have a rough texture with many "loose" fibers. Sometimes these fibers can get caught in between the stitches of the embroidered design and look unsightly. To prevent this, a transparent sheet of topping material is placed over the design area. The design is then stitched through the topping, fabric, and backing material. When the design is complete, the topping material is removed by wetting it with water. Topping is not always needed and depends on the type of fabric being stitched.