Performance wear is the fastest growing segment of the apparel industry globally, with 9 out of 10 people now wearing their sportswear for activates other than exercising. New technology has seen an increase in the variety of fabrics with functional properties used for sports / fashion garments.
With thermal, light-weight and stretchy fabrics becoming increasingly popular it’s something an industrial embroiderer can’t avoid. Such fabrics can be notoriously difficult to embroider, with holes, puckering and fabric slipping causing major problems.
It’s a common misconception that polyester thread is best for performance wear. Rayon viscose thread performs just as well while providing a softer finish. Madeira Classic is made from natural fibres, although it is not bleach resistant.
Avoid overstretching the fabric during hooping, as this can lead to puckering once the tension is released. A stable, natural tension is key.
To minimise damage such as holes or laddering in fabrics like Lycra, opt for ballpoint needles (SES) in the smallest size suitable for your chosen thread.
Reduce the risk of distortion by digitising designs to stitch outwards and keeping stitch counts as low as possible. Slightly loosening thread tension can also help reduce stress on delicate fabrics.
Without proper stabilisation, fabrics can move during stitching, leading to puckering, distortion, and uneven lettering.
SuperCut Weblon, a specialist 44g cut-away backing, is designed specifically for stretchy and difficult-to-frame fabrics. It provides excellent stability without adding unnecessary bulk, making it particularly suitable for garments such as sportswear, activewear, fashion basics, and other close-fitting items.
The quality of embroidery is judged not only by the appearance, but also by the comfort and finish on the inside of the garment. Exposed stitches and backing materials can sometimes feel rough against the skin, particularly on lightweight garments or items worn close to the body.
For added comfort and a premium finish, covering the reverse side of embroidery with heat-activated Comfortwear creates a smooth, soft feel against the skin.
Not every embroidery design is suitable for every fabric type. Lightweight and stretchy materials naturally have more movement and less structural support than heavier fabrics, which means they can struggle to handle extremely dense or highly detailed embroidery. Guiding customers towards more embroidery-friendly designs can significantly improve results and help avoid common issues.
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