Polyester performance apparel can be embroidered just as easily as cotton apparel with just a few minor adjustments in equipment or processes.


Using a ball point needle will help to avoid cutting the fabric when running an embroidery logo. Also consider using a 70/10 needle when running on lighter weight performance fabrics


Polyester and Rayon threads are both fine to use, but a Rayon thread may actually look and feel a little better on the lighter weight fabrics due to its softer hand. Regardless of which type of thread used, a #40 thread is probably best when used with the 70/10 needles.


Stick with backings that are lighter than 2.0 oz. Tear away and cut away backings are both good, but always cut away the backing when cleaning up the logo. Pulling on the backing to remove it may lead to stretching or distorting some lighter weight fabrics.

Stitch Density

Too many stitches in a logo intended for performance apparel could result in puckering and even needle cuts. Reduce the overall stitch density and focus more on the underlay. Proper underlay coverage will help with stability as well as help with coverage when reducing the density of the step fill or satin stitch.


Hooping performance apparel too tightly may result in hoop burns, damaged fabric, or puckering in the embroidery. Hoop the garment just tight enough to stay within the hoop when being embellished without forcing the garment into the hoop. Also, do not try to adjust the fabric after it has already been hooped.