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?
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.