How to Order Custom Shirts: Printing vs. Embroidery, Minimums, and Logo Setup

Updated

Choose embroidery for polos, hats, and small left-chest logos that need to survive repeated washing; choose printing for large graphics, gradients, and budget T-shirts. Before you order, confirm three things with the supplier: the minimum quantity, whether logo setup costs extra, and the turnaround time. Queensboro, for example, advertises no minimums, free logo setup, and embroidery and printing experience dating to 1982, with shipping from Wilmington NC, Dallas TX, and Reno NV.

Embroidery vs. printing: pick by shirt and logo

Factor Embroidery Printing
Best on Polos, hats, outerwear, workwear, left-chest logos T-shirts, sweatshirts, large front/back designs
Logo complexity Simple shapes, text, limited colors work best Handles gradients, fine detail, many colors
Durability Stitched thread holds up to frequent washing Can crack or fade over time depending on method
Feel Raised texture, heavier on thin fabrics Flatter, softer on lightweight shirts
Typical use Company logo shirts, uniforms, team polos Event shirts, giveaways, promotional tees

A practical rule: if the logo is a small chest mark on a polo or cap, embroider it. If the design covers a large area or uses photographic detail, print it.

Check minimums and per-unit pricing first

Minimum order quantities vary widely by supplier and decoration method. Queensboro states it has no minimums, which matters if you need a handful of shirts for a small team rather than a bulk run. Ask for the per-unit price at your actual quantity, not the bulk rate, and confirm whether setup or digitizing fees apply. Queensboro advertises free logo setup; other suppliers may charge a one-time digitizing fee for embroidery or a screen setup fee per color for printing.

Prepare a usable logo file

  • Vector files (AI, EPS, PDF) scale cleanly for both embroidery and printing.
  • High-resolution PNG works for printing but may need cleanup for embroidery.
  • Low-resolution JPGs often need redrawing, which can add cost or delay.

For embroidery, the supplier converts your logo into a stitch file, so simple, high-contrast designs digitize better. Confirm the thread colors against a physical or digital color chart before production.

Confirm sizing, colors, and turnaround before ordering

  1. Check the size chart for each specific shirt style, since fits differ between brands and between men's, women's, and youth cuts.
  2. Request a color swatch or confirm the exact shirt color and thread or ink color.
  3. Ask for the production and shipping timeline in writing, and note the ship-from locations if delivery speed matters.
  4. Place a small sample order first if the design is complex or the deadline is tight.

Know your recourse if something goes wrong

Ask about the supplier's guarantee before you pay. Queensboro's No Returns Necessary Guarantee states that if a size, thread color, address, or product issue occurs, you contact them and they fix it with a replacement or refund without requiring a product return. Get any guarantee terms in writing so you know what is covered for wrong sizes, color mismatches, or print defects.

Quick checklist before you click order

  • Decoration method matches the shirt type and logo complexity
  • Minimum quantity and per-unit price confirmed at your order size
  • Logo file is vector or high-resolution, with colors approved
  • Size chart checked for every style in the order
  • Turnaround time and shipping origin confirmed against your deadline
  • Guarantee and return policy understood