One of the most common challenges in embroidery is working with polo shirts – particularly sportswear styles made from very thin polyester fabrics. These materials are prone to puckering and even developing small holes during embroidery, often leaving unsatisfactory results.
There isn’t a single quick fix, as puckering usually occurs due to a combination of factors. The most common issues include:
Why Does Puckering Happen?
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Poor digitising
Inexpensive digitising services are often created by individuals with little or no embroidery experience. Poorly digitised designs place unnecessary stress on delicate fabrics, causing distortion and puckering. -
Incorrect thread tension
Thread tension plays a crucial role in embroidery quality. When set too tightly, the thread stretches during stitching and relaxes afterwards, resulting in puckering. This problem is often overlooked if tensions are only adjusted occasionally during machine servicing. -
Inappropriate backing
Using a lightweight 40g tear-away backing may appear convenient, but on thin polyester fabrics it can perforate or detach before embroidery is complete. Without adequate support, puckering is far more likely.
The Smarter Solutions
To prevent these problems, specialist embroidery backings can provide the necessary stability and support for lightweight fabrics:
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Super Spun Backing
A translucent, ultra-light cut-away backing that is extremely strong. It does not shift or perforate during embroidery. After stitching, cut around the design for a soft and comfortable finish. -
Soft & Strong Backing
Available in 40g, 50g and 80g weights, this cut-away backing allows stitches to sink neatly into the material without breaking through. Once embroidery is complete, cut around the design for a clean result that remains comfortable to wear.
By combining correct digitising, appropriate thread tension, and the right backing, puckering can be dramatically reduced or eliminated. These adjustments ensure cleaner embroidery, protect the garment, and create a more professional finish. For more information or to speak with one of our embroidery experts, contact us today here.