My customers are constantly looking for smaller and smaller letters for their corporate logos. What is the shortest reasonable letter length that I can produce on a commercial embroidery machine?

Answer

Just when you thought you couldn’t get any smaller than about 1/4" for letters, along came 60-weight thread, which can produce 3 mm-high letters. Some manufacturers also offer a 75-weight thread, capable of producing letters that are 2.5 mm high. The 75-weight variety is a polyester thread that will hold up to being laundered in wash water with bleach. It requires use of a #60/8 needle for best results. Along with producing incredibly small letters and detail, 75-weight thread can also be used for attaching small sequins and for producing very intricate filigree embroidery. Try to avoid fonts with serifs in order to achieve maximum clarity.

Madeira USA