Promotional merchandise provides numerous opportunities to display your brand, turning everyday items into tools for connection and visibility. With various decoration techniques available, it can be challenging to choose the most suitable one for your specific needs.
This guide aims to assist in this decision-making process.
It will examine the advantages and disadvantages of several popular decoration methods, including digital printing and embroidery, enabling you to make decisions that align with your brand’s style, objectives, and budget. Whether you seek bold and colourful designs or simple and understated finishes, this guide covers all options.
Print options, explore how to effectively highlight your logo.
Embroidery
Pad Printing
Screen Printing
Faux Embroidery
Digital Heat Transfer
Laser Engraving
Direct Digital Printing
Rotary Screen Printing
Foil Printing
Rotary Digital Printing
Sublimation Printing
Hot Stamping
Imitation Etch Printing
Patches
Resin Coated Finish
Digital Labels
Embroidery
Embroidery is a premium decoration technique that stitches a design directly into fabric, offering a durable and high-quality finish. Ideal for elevating apparel and textile products, embroidery adds texture, dimension, and a sophisticated touch.
Popular Uses: Caps, polo shirts, jackets, backpacks, towels.
BENEFITS:
• High perceived value enhances brand prestige.
• Long-lasting and resistant to wear.
• Adds a professional, textured look to designs.
• Requires only one setup charge.
• Perfect for textiles and structured products like caps.
CONS::
• PMS colour matching is approximate and limited to available thread colours.
• Individual naming or variable data is typically not feasible.
• Higher costs compared to printing, as pricing depends on stitch count.
• Unsuitable for large decoration areas.
Limitations:
• Artwork must be supplied in vector format for digitization.
• Avoid fine details or fonts smaller than 5mm to ensure clarity.
Embroidery is a timeless choice for creating durable, polished branding on high-quality items.
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Pad printing is a versatile method that uses a silicone pad to transfer ink from an etched plate onto the product. It excels at printing fine details on irregular or curved surfaces, making it ideal for compact and uniquely shaped items.
Popular Uses: Pens, keyrings, mugs, USB drives, golf balls, and other small or curved products.
BENEFITS:
• Delivers high-detail prints, with precision as fine as 0.5mm.
• Suitable for curved or uneven surfaces.
• Close PMS colour matches achievable on white or light-coloured objects.
• Metallic gold and silver inks available for added flair.
• Multi-colour registration allows up to 5 colours with precise alignment.
CONS::
• Cannot accommodate variable data, such as individual names.
• Limited decoration area.
• Darker products may require a base white print for accurate colours, adding cost.
• Each colour requires separate setup, increasing time and expense.
Limitations:
• Artwork must be supplied in vector format for best results.
• Minimum text size is typically 5pt to maintain clarity.
• Neon/fluorescent colours are not available.
Pad printing is perfect for adding intricate designs to smaller, curved items with a professional finish.
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Screen printing is a widely used technique where ink is pushed through a stencilled mesh screen onto the product’s surface. It’s ideal for bold, vibrant designs and works effectively on a variety of flat materials.
Popular Uses: T-shirts, tote bags, umbrellas, notebooks, towels, and other flat products.
BENEFITS:
• Offers a large decoration area on flat surfaces.
• Cost-effective for high-volume orders.
• Provides close PMS colour matching for vibrant results.
• Fluorescent and metallic inks available for textiles.
• Supports multi-colour registration, allowing up to 5 colours with precise alignment.
CONS::
• Matching PMS colours on darker products is challenging and may require a white base coat, increasing costs.
• Cannot print variable data, such as individual names.
• Each colour requires separate setup, adding time and cost.
Limitations:
• Artwork must be provided in vector format for optimal quality.
• Fine details (e.g., text smaller than 1mm) may infill.
• Difficult to achieve smooth colour gradients.
Screen printing is perfect for creating eye-catching, high-impact designs on a wide range of flat products.
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Introducing Faux Embroidery, a revolutionary digital printing technique that mimics the look of traditional embroidery with remarkable precision. This innovative method creates a realistic, full-colour embroidered effect that’s lightweight, flexible, and soft to the touch.
Why Choose Faux Embroidery?
Unlike traditional embroidery, Faux Embroidery eliminates the limitations of stitching, offering a faster, more versatile, and cost-effective way to achieve a high-end, textured appearance.
Perfect For: Apparel, accessories, and promotional items where a premium finish is desired without the added expense or complexity of stitched embroidery.
With its vibrant detail and exceptional adaptability, Faux Embroidery elevates your branding to a smarter, bolder level. Achieve a luxury aesthetic and leave a lasting impression—without compromise
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Digital Heat Transfers
Digital Heat Transfers are a versatile decoration technique that involves printing a design onto transfer paper and heat-pressing it onto a product. Known by names like Supacolour, Colourflex, or Power Print, this method is perfect for creating vibrant, full-colour designs with gradients and complex details.
Popular on: Bags, T-shirts, jackets, backpacks, and caps.
BENEFITS:
• Unlimited Colour Options: Achieves vibrant, full-colour designs with gradients.
• Durable and Flexible: Withstands wear and tear while maintaining flexibility.
• Fast Setup: Requires only a single setup, streamlining production.
• Variable Data: Allows personalization for some items.
• Quick Production Times: Ideal for fast turnaround projects.
CONS:
• A thin clear glue line may sometimes appear around designs.
• Pricing scales with print size—larger designs may cost more.
Limitations
• Requires heat for application, limiting compatibility with some materials.
• Artwork must be in vector format or high-resolution bitmap for optimal quality.
• Minimum recommended detail size: 1mm.
Digital Heat Transfers are a reliable choice for bold, detailed, and long-lasting branding.
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Laser Engraving uses a focused laser to remove material from the product's surface, producing a precise, permanent design. This method is ideal for creating high-quality, long-lasting branding on metal, wood, and glass items.
Popular on: Pens, drink bottles, glassware, cheeseboards, and other metal or wooden products.
BENEFITS:
• Premium Finish: Offers a high-value, professional appearance.
• Durable: Becomes a permanent part of the product’s surface.
• Large Branding Areas: Suitable for curved products like drink bottles.
• Personalization: Allows for variable data (e.g., individual names) on select items.
CONS:
• On wood (e.g., bamboo), branding may vary due to natural grain differences.
• Finish colour depends on the material and cannot be altered.
• Fine details may not appear clearly on smaller items like pens.
Limitations
• Best suited for specific materials (metal, glass, wood).
• Artwork must be supplied in vector format for optimal results.
Laser engraving is an excellent choice for durable, elegant, and professional branding that leaves a lasting impression.
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Direct Digital Printing transfers ink directly from inkjet print heads onto the product, allowing for vibrant, full-colour designs. This method is ideal for achieving intricate, high-quality prints on flat, hard-surface items.
Popular on: Notebooks, pens, power banks, stationery, and other flat or slightly curved products.
BENEFITS:
• Unlimited Colours: Perfect for complex, full-colour designs and gradients.
• Variable Data: Supports personalization, such as individual names or serial numbers, on select products.
• Large Print Area: Covers substantial surfaces for bold branding.
• Dark Surface Compatibility: A white base layer can enhance prints on darker products.
Limitations
• Limited usability on curved or uneven surfaces.
• Larger print areas may incur higher costs.
• Some products require a 3mm bleed in the artwork.
• Artwork must be provided in vector format or high-resolution bitmap for best results.
Direct digital printing is a versatile solution for precise, vibrant branding on a range of products, offering flexibility and stunning results.
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Rotary Screen Printing uses a fine mesh screen and squeegee to apply ink, making it ideal for cylindrical items like drink bottles, pens, and coffee cups. This method ensures sharp, durable prints and supports large branding areas.
BENEFITS:
• Supports large print areas.
• Offers close PMS colour matches on light products.
• Cost-effective for bulk orders.
• Metallic inks (gold and silver) available.
CONS:
• Limited to one colour for some products due to registration challenges.
• Cannot print variable data (e.g., individual names).
• May require a white base coat for colour accuracy on dark items, adding cost.
• Fine details may blur or fill in.
Artwork Requirements
• Artwork must be in vector format to ensure optimal print quality.
Rotary Screen Printing produces sharp, durable prints on cylindrical items. It’s cost-effective, supports large areas, metallic inks, but limited in colours and fine detail accuracy.
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Foil Printing
Foil Printing uses heat and pressure to apply metallic foil, creating an elegant finish. Modern digital foiling enhances flexibility and eliminates the need for plates.
Popular on: Notebooks, gift boxes.
BENEFITS:
• Premium, high-value appearance.
• Supports variable data (e.g., individual names).
• Flexible foil works on textured and soft-touch surfaces.
CONS:
• Fine details may be lost on textured surfaces.
• Limited product range (e.g., notebooks)
Limitations
• Requires vector artwork.
• Minimum line thickness: 1mm (textured), 0.4mm (smooth).
Foil Printing adds elegance to products using metallic foil. Ideal for notebooks and gift boxes, it supports custom names but struggles with textured surfaces and details.
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Rotary Digital Printing
Rotary Digital Printing applies ink directly to products using inkjet technology, delivering full-colour prints with exceptional vibrancy and spot colour matching.
Popular on: Drink bottles, reusable coffee cups/tumblers.
BENEFITS:
• Large decoration areas.
• Unlimited colours and vibrant prints.
• Single setup charge.
• Matte or gloss finish options available.
CONS:
• Higher cost compared to rotary screen printing.
• Limited production capacity may extend lead times.
Limitations
• Requires vector or high-resolution bitmap artwork.
• A small gap may be necessary, preventing full wrap-around designs.
Rotary Digital Printing creates vivid, full-colour designs on cylindrical products. Ideal for bold branding but involves higher costs and limited capacity compared to screen printing.
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Sublimation Printing uses heat to convert dye into gas, bonding it directly with polyester or polymer-coated materials for vivid, durable, and seamless designs.
Popular on: Towels, apparel, coffee mugs, bags.
BENEFITS:
• Dye infuses into material, ensuring long-lasting prints.
• Allows for edge-to-edge printing on most items.
• Unlimited full-colour designs possible.
• Variable data printing available on some products.
• Requires only one setup cost.
CONS:
• Limited to specific materials with white surfaces.
• White, metallic, and fluorescent colours are challenging to reproduce.
Limitations
• Artwork must be vector or high-resolution bitmap.
• Bleed area required for edge-to-edge designs.
Sublimation Printing delivers vibrant, durable designs by infusing dye into polyester materials. Ideal for edge-to-edge designs but limited to specific surfaces and colour ranges.
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Hot Stamping uses a heated metal plate to apply an indented design onto the product, creating a permanent, high-quality finish.
Popular on: Cheeseboards, chopping boards.
BENEFITS:
• Creates a high-value, premium finish
• Permanent, lasting imprint on the product.
• Provides a visually appealing result.
CONS:
• Not suitable for variable data printing.
• The finish may vary slightly between products.
Limitations
• Minimum line thickness: 0.4mm.
• Artwork must be supplied in vector format for optimal quality.
Hot Stamping delivers a premium, permanent finish, ideal for wood. While it offers high value, it’s limited by design thickness and lack of variable data.
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Imitation Etch Printing uses specialized ink applied through pad or screen printing to create an etched effect on glass products.
Popular on: Wine glasses, beer glasses, and other glassware.
BENEFITS:
• Offers a high-value appearance at a lower cost than real etching.
• Can be applied to curved surfaces.
CONS:
• Cannot print variable data.
• Requires longer production times due to the curing process.
Limitations
• Artwork must be supplied in vector format for optimal quality.
Imitation Etch Printing provides an affordable, high-value etched look for glassware. While versatile and cost-effective, it lacks variable data printing and requires longer production time.
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Patches
Patches are crafted with tightly woven threads for sharp details and vibrant colors, then embroidered onto products for a durable, professional finish. Other methods like Supasub, Supaetch, and Supaflex offer additional customization options, such as full-color badges, laser-etched suede patches, and high-detail logos with matte or gloss finishes.
Popular on: Caps, jackets, backpacks, sports bags, uniforms.
BENEFITS:
• Offers similar value perception to embroidery.
• Economical price.
• Various patch styles available, including embroidered, engraved, and sublimated.
• Fine detail and unlimited color options can be achieved.
CONS:
• Not suitable for lightweight fabrics.
• Limited flexibility.
Limitations
• Artwork must be supplied in vector format or high-resolution bitmap for optimum quality.
Patches offer a professional finish at an affordable price with various styles and color options. They’re ideal for durable fabrics but less flexible for lightweight materials.
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This process uses CMYK printing to transfer artwork onto adhesive-backed vinyl, which is then coated with a clear resin for a glossy, durable finish. After curing, the decal forms a permanent bond with the product.
Popular on: Keyrings, lapel pins, name tags.
Pros
• Full colour printing.
• Creates a 3D effect.
• Can be printed edge to edge.
• Only one setup cost required.
CONS:
• Not ideal for large print areas.
• Production time may be longer as the resin requires curing.
Limitations
• Vector or high-resolution bitmap format is required.
• A bleed area must be added to the artwork.
Resin Coated Finish offers vibrant, 3D full-colour prints with a glossy finish. It’s ideal for small areas but may take longer to produce.
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Digital labels are high-quality, full colour printed stickers that are applied to products. These labels can include variable data like barcodes for added functionality.
Popular on: Confectionery, sunscreen, hand sanitiser.
BENEFITS:
• Unlimited full-colour printing.
• Cost-effective.
• Custom shapes and edge-to-edge printing.
• Only one setup charge required.
CONS:
• Less durable than other decoration options, typically best for packaging or giveaway items.
• Lower perceived value compared to other decoration types.
Limitations
• White print may not be achievable on clear, silver, or gold stock.
• Artwork must be supplied in vector format or high-resolution bitmap for optimum quality.
Digital Labels offer vibrant, full-colour prints at a cost-effective price. Ideal for packaging, but less durable and with lower value perception than other methods.