Embroidery
Stitch density
Stitch density is how tightly embroidery stitches are packed per area, typically set as row spacing between roughly 0.3mm and 0.6mm, controlling both appearance and fabric hand.
Two logos can share identical artwork and even the same stitch count and still feel completely different in the hand — that's stitch density doing its job. Density is set by row spacing inside a fill or satin area, usually somewhere between about 0.3mm (tight) and 0.6mm (open); tighter spacing packs more thread into the same square inch.
Go too loose and the backing or the garment fabric shows through the stitches — a washed-out, thin look, especially in a bold logo color like navy or black. Go too tight and the patch of fabric under the design turns stiff and board-like; on a lightweight tee, an overdense 3-inch chest logo can feel like a stuck-on patch rather than part of the shirt. We've had customers return shirts thinking the embroidery was defective when really it was just overdensified for the fabric weight — a stitch density problem, not a manufacturing defect.
Digitizers dial density to the garment: denser on structured items like caps and heavier canvas, lighter on jersey knits and fleece where the fabric already has texture and give. Density also interacts with thread weight and fabric color — lighter thread on dark fabric sometimes needs slightly more density for full coverage.
A common mistake is assuming higher stitch count always means better quality. Stitch count is partly a function of stitch density, and pushing density past what a fabric can handle doesn't improve the look — it just adds stiffness and cost without adding definition.