Mixing screen print and embroidery in one uniform program
Most restaurant orders Battle Born Clothing builds use both: printed tees for the kitchen, embroidered aprons, polos and hats for everything else. Here is how to set it up so the logo matches and the fees stay small.
Which method for which piece
| Piece | Method | Why |
|---|---|---|
| Kitchen and bar tees, 48+ | Screen print | Cheapest per piece on a simple logo; tees get replaced anyway |
| Tees under 48 | Embroidery or DTF | Screens do not pay off on small runs |
| Aprons | Embroidery | Survives daily bleach |
| Polos | Embroidery | Standard for collared shirts |
| Hats | Embroidery or leather patch | Patch for merch, embroidery for uniform |
| Full-color art, any piece | DTF | No screens, any color count |
One logo, two preparations
Embroidery needs a digitized file ($18.99 once). Screen print needs a screen per color ($20 each). Both start from the same vector art, but thin lines and tiny text that print fine will not stitch. We usually simplify the embroidered version slightly and show both on one proof so they read as the same mark.
Color matching
Ink and thread are different materials, so an exact match is not possible; a close one is. Send Pantone or hex values. We pick the closest plastisol and the closest Rapos thread and show both on the proof.
Fees in a mixed order
- Digitizing: $18.99 once per embroidered design.
- Screens: $20 per color. A one-color logo front and back is two screens, $40.
- Flash: $0.25 per flash on dark garments, included in the $4.59 figure.
- No additional setup for running both methods in one order.
A worked mixed order
| Line | Qty | Each | Total |
|---|---|---|---|
| PC61 tee, 1-color front print, dark (48 pcs) | 48 | $10.63 | $510.24 |
| Screen | 1 | $20.00 | $20.00 |
| A500 apron, embroidered (48-71 tier: 62 embroidered pieces, one logo) | 30 | $19.48 | $584.40 |
| K500 polo, embroidered (48-71 tier: 62 embroidered pieces, one logo) | 8 | $19.05 | $152.40 |
| Richardson 112, embroidered (48-71 tier: 62 embroidered pieces, one logo) | 24 | $20.00 | $480.00 |
| Digitizing | 1 | $18.99 | $18.99 |
| Total | $1,766.03 |
The printed tees are the cheapest line per piece and the embroidered pieces are the ones that will still look right next year.
Keeping the logo the same size everywhere
A logo that is 4 inches wide on a tee print and 3.5 inches on an apron bib and 2 inches on a cap front will still read as one brand if the proportions and colors match. We size each placement to the garment and show all of them on one proof. If you want a hard rule: left chest and apron bib at 3.5 inches wide, cap front at 2.25 inches tall, full front print at 10 to 12 inches wide. Ask on the proof if you want something different.
Reorders across both methods
Digitized files are kept forever. Screens are not; they are reclaimed after the job, so a print reorder means a new $20 screen per color. That is one more reason to print the pieces you replace in bulk once a year and embroider the pieces you top up in small batches.
Timeline
A mixed order ships together 28 days after you approve the proof. If the tees are urgent for an opening and the aprons can follow, say so; rush is quoted per job.
Send the whole position list on the quote form and we will split it by method for you.
Questions
Does mixing methods cost more?
No. You pay the normal one-time fees for each method (digitizing, screens) and the per-piece rates. There is no surcharge for combining them.
Can you print tees and embroider the same tee?
Yes, for example a printed back and an embroidered left chest. Priced as two decorations; quoted per job.
Will the printed and embroidered logos look identical?
Close, not identical. Thread has texture and a slightly simplified shape. The proof shows both so you can approve them together.