Logo on merchandise and souvenirs: technical requirements
Resolution and formats: why a universal file does not exist
Standard 300 dpi at scale 1:1 is the base for raster elements, but further requirements diverge depending on the method.
| Method | File format | Features of preparation |
|---|---|---|
| Sublimation | PDF, EPS, TIFF (300 dpi) | Requires polyester fabric of at least 65%, colors in CMYK, no restrictions on the number of shades |
| Embroidery | DST, EMB (non-vector file!) | Palette is limited to ~120 thread colors, each color requires a separate layer, lines must not be thinner than 1 mm |
| Screen printing | AI, EPS, curves | Handles small details well, but no more than 4-6 colors per stencil |
| UV printing | AI, PDF, CMYK/Pantone | Allows gradients and tints, requires a matrix for accurate color registration |
The error that is most commonly made: sending a raster JPG with a logo to the manufacturer for embroidery. The embroidery machine software does not work with pixels, but with stitch trajectories — the file will have to be digitized again, and the line thickness of 0,3 mm on the screen will become an unreadable blob of thread on the fabric.
Size: between 'not visible' and 'too much'
The minimum size of a logo is determined not by aesthetics, but by the physical limit of readability of the application method. For embroidery, text smaller than 4-5 mm in height becomes a mess of threads. For tampographic printing, the lower boundary is around 3 mm on the item. The maximum is limited even more strictly: a logo that covers the entire chest of a t-shirt looks like advertising, not a brand.
- Men's t-shirt — printing on the chest center approximately 28–30 cm in width (recommended maximum 300×420 mm for a solid image)
- Women's t-shirt — printing on the chest approximately 23–28 cm in width (the fit is tighter, the area is smaller)
- Maximum on the chest — 300×420 mm, beyond that the composition begins to skew
- Sleeve — 105×148 mm, only for compact versions of the logo
- Distance from the collar — 7,5-10 cm (3-4 inches), this is a standard that should not be violated without reason
Overhang and allowances: why a design needs a 'safety margin'
Overhang is the area of the image beyond the final size of the product, which is cut off after printing. For merchandise with printing at the edge, the standard is 2-5 mm on each side. Without this margin, on items with uneven edges (mugs, badges, stickers), even the slightest shift during production will result in a white stripe along the contour.
The reverse rule applies to important elements — text, logo details: they must be inset from the edge of the design by at least 2 mm inward. This is critical for products with irregular contours — engravings on metal, embossing on leather — where the tolerance of the cutting tool or press may 'eat into' the edge of the image.
Case: dark t-shirts and a logo that was 'unreadable'
Real situation: a clothing brand ordered a batch of dark blue t-shirts with a white logo using direct printing. The design was sent in CMYK, without accounting for the base color. The first test batch came out with a gray, dull logo — the ink partially absorbed into the dark fibers and lost its brightness.
The reason is that on dark fabrics, a substrate must be applied under colored images — an additional layer of white ink that creates a base for the upper colors. This is a separate technological operation, and it increases printing costs by 15-30%. The manufacturer did not include it in the default calculation, and the customer did not ask. After renegotiating the design with the substrate, the logo became bright and contrasted, but the run had to be reprinted — resulting in a loss of time and budget.
The bottom line is simple: when ordering on a colored or dark background, always check with the manufacturer whether the substrate is included in the calculation, and request a sample before launching the print run.
Errors in the layout and the specific defects they cause
Each typical error in file preparation results in a predictable defect on the product — and it's more convenient to know this in advance than to figure it out afterward.
| Error in the layout | What will result on the product |
|---|---|
| Font not converted to curves | Replacement with the manufacturer's system font, distorted letters |
| Raster effects (shadow, glow, gradient in RGB) | Blurred edges, 'muddy' transitions, unpredictable color during printing |
| Too thin lines for embroidery | Thread flaking off, broken stitch, contour deformation |
| RGB color model instead of CMYK/Pantone | Tone shift, acidic or washed-out colors instead of brand colors |
| Hidden/invisible layers in the file | The manufacturer prints what should not be visible — extra elements or duplicates |
It is worth noting about color: deviation from the reference Pantone by ±5-15% is normal, not a defect, especially when printing on colored products. This margin should be built into expectations from the start, rather than demanding absolute identity with the original on screen from each batch.
How to adapt one logo for different methods and products
Preparing a universal 'master file' is meaningless — the correct approach is to keep several versions of the logo for different tasks.
- Vector version in curves, CMYK — the base for tampography, UV and full-color printing
- Simplified version with a limited palette (up to 6-8 colors) — for methods with limitations on the number of inks or threads
- Monochrome version — for engraving, embossing, laser cutting, where gradients are physically impossible
- Inverted version (light logo on dark background) — for dark products where a substrate is needed
Before finalizing the layout with the manufacturer, it is worth asking four questions: what method of application is definitely used, is a substrate needed and how it affects the estimate, in what format the file is accepted and what color tolerance is considered normal for this run. These four answers eliminate most claims at the stage of receiving the finished batch.
| Method | File format | Features of preparation |
|---|---|---|
| Sublimation | PDF, EPS, TIFF (300 dpi) | Requires polyester fabric of at least 65%, colors in CMYK, no restrictions on the number of shades |
| Embroidery | DST, EMB (non-vector file!) | Palette is limited to ~120 thread colors, each color requires a separate layer, lines must not be thinner than 1 mm |
| Screen printing | AI, EPS, curves | Handles small details well, but no more than 4-6 colors per stencil |
| UV printing | AI, PDF, CMYK/Pantone | Allows gradients and tints, requires a matrix for accurate color registration |
The error that is most commonly made: sending a raster JPG with a logo to the manufacturer for embroidery. The embroidery machine software does not work with pixels, but with stitch trajectories — the file will have to be digitized again, and the line thickness of 0,3 mm on the screen will become an unreadable blob of thread on the fabric.
Size: between 'not visible' and 'too much'
The minimum size of a logo is determined not by aesthetics, but by the physical limit of readability of the application method. For embroidery, text smaller than 4-5 mm in height becomes a mess of threads. For tampographic printing, the lower boundary is around 3 mm on the item. The maximum is limited even more strictly: a logo that covers the entire chest of a t-shirt looks like advertising, not a brand.
- Men's t-shirt — printing on the chest center approximately 28–30 cm in width (recommended maximum 300×420 mm for a solid image)
- Women's t-shirt — printing on the chest approximately 23–28 cm in width (the fit is tighter, the area is smaller)
- Maximum on the chest — 300×420 mm, beyond that the composition begins to skew
- Sleeve — 105×148 mm, only for compact versions of the logo
- Distance from the collar — 7,5-10 cm (3-4 inches), this is a standard that should not be violated without reason
Overhang and allowances: why a design needs a 'safety margin'
Overhang is the area of the image beyond the final size of the product, which is cut off after printing. For merchandise with printing at the edge, the standard is 2-5 mm on each side. Without this margin, on items with uneven edges (mugs, badges, stickers), even the slightest shift during production will result in a white stripe along the contour.
The reverse rule applies to important elements — text, logo details: they must be inset from the edge of the design by at least 2 mm inward. This is critical for products with irregular contours — engravings on metal, embossing on leather — where the tolerance of the cutting tool or press may 'eat into' the edge of the image.
Case: dark t-shirts and a logo that was 'unreadable'
Real situation: a clothing brand ordered a batch of dark blue t-shirts with a white logo using direct printing. The design was sent in CMYK, without accounting for the base color. The first test batch came out with a gray, dull logo — the ink partially absorbed into the dark fibers and lost its brightness.
The reason is that on dark fabrics, a substrate must be applied under colored images — an additional layer of white ink that creates a base for the upper colors. This is a separate technological operation, and it increases printing costs by 15-30%. The manufacturer did not include it in the default calculation, and the customer did not ask. After renegotiating the design with the substrate, the logo became bright and contrasted, but the run had to be reprinted — resulting in a loss of time and budget.
The bottom line is simple: when ordering on a colored or dark background, always check with the manufacturer whether the substrate is included in the calculation, and request a sample before launching the print run.
Errors in the layout and the specific defects they cause
Each typical error in file preparation results in a predictable defect on the product — and it's more convenient to know this in advance than to figure it out afterward.
| Error in the layout | What will result on the product |
|---|---|
| Font not converted to curves | Replacement with the manufacturer's system font, distorted letters |
| Raster effects (shadow, glow, gradient in RGB) | Blurred edges, 'muddy' transitions, unpredictable color during printing |
| Too thin lines for embroidery | Thread flaking off, broken stitch, contour deformation |
| RGB color model instead of CMYK/Pantone | Tone shift, acidic or washed-out colors instead of brand colors |
| Hidden/invisible layers in the file | The manufacturer prints what should not be visible — extra elements or duplicates |
It is worth noting about color: deviation from the reference Pantone by ±5-15% is normal, not a defect, especially when printing on colored products. This margin should be built into expectations from the start, rather than demanding absolute identity with the original on screen from each batch.
How to adapt one logo for different methods and products
Preparing a universal 'master file' is meaningless — the correct approach is to keep several versions of the logo for different tasks.
- Vector version in curves, CMYK — the base for tampography, UV and full-color printing
- Simplified version with a limited palette (up to 6-8 colors) — for methods with limitations on the number of inks or threads
- Monochrome version — for engraving, embossing, laser cutting, where gradients are physically impossible
- Inverted version (light logo on dark background) — for dark products where a substrate is needed
Before finalizing the layout with the manufacturer, it is worth asking four questions: what method of application is definitely used, is a substrate needed and how it affects the estimate, in what format the file is accepted and what color tolerance is considered normal for this run. These four answers eliminate most claims at the stage of receiving the finished batch.
Recent articles
MegaFon, BMW, VTB and more 240+ companies. See how it looks in the showcase reel:
Our branding agency is approached to order:
Branding agency services
