How to embroidery on Polyester Fabric - All You Need to Know

Polyester fabric, as you may know, has become a staple in our lives. From clothing to home textiles, it's everywhere. It's durable, easy to care for, and resistant to wrinkles and stains. That makes it an excellent canvas for embroidery – a craft that allows you to add a personal touch and embeazllish various items. The possibilities are truly endless when it comes to polyester embroidery.

If you've ever wondered how to navigate the world of embroidering on polyester fabric, you've come to the right place. In this blog, we're going to provide you with all the essential information you need to master the art of embroidery on polyester.

So, without any ado, let’s get started…

Understanding Polyester Fabric

Polyester fabric, a versatile material commonly used in various applications, has become a sought-after choice for embroidery enthusiasts. To achieve success in your polyester embroidery projects, it's essential to understand the fabric itself. In this section, we'll delve into the fundamentals of polyester fabric, the different types and blends available, and the characteristics that are particularly relevant when it comes to embroidering on this medium.

What is polyester fabric?

Polyester fabric is a synthetic textile made from polyester fibers, and it has gained widespread use due to its durability, affordability, and resistance to wrinkles and stains. As a popular choice for clothing, home decor, and more, polyester offers several advantages for embroidery enthusiasts.

  • Polyester fabric is a man-made textile derived from polyester fibers.
  • It's known for its durability, affordability, and ease of care.
  • Commonly used in clothing, household items, and accessories.

Different types and blends of polyester

Polyester isn't a one-size-fits-all fabric; it comes in various types and blends, each with its unique properties. Understanding the distinctions between these can help you make informed choices for your embroidery projects.

  • Types of polyester fabric include PET, PCDT, and PTT, with PET being the most common.
  • Blends, such as cotton-polyester and wool-polyester, offer different textures and properties.
  • Polyester microfibers create a soft and silky fabric ideal for delicate embroideries.

Characteristics of polyester fabric relevant to embroidery

Polyester fabric brings specific attributes to the table that impact the embroidery process. Being informed about these characteristics will help you choose the right materials and techniques for your embroidery on polyester.

  • Polyester's smooth surface is conducive to detailed embroidery work.
  • It's resistant to wrinkles, making your embroidered designs appear crisp and clean.
  • The fabric's moisture-wicking properties can affect the choice of stabilizers and thread.

How to Embroider on Polyester Fabric

Embroidering on polyester fabric is a unique and rewarding craft that offers endless creative possibilities. Well, let’s start exploring everything you need to know to master the art of embroidery on polyester.

Preparing Your Workspace

Before you embark on embroidery on polyester journey, you must set the stage with a conducive workspace that allows you to focus and create without unnecessary hindrances. Here's what you need to do:

  1. Choose the right embroidery machine and needle: Select an embroidery machine capable of handling polyester fabric. A machine with adjustable speed settings and hoop sizes is ideal. Also, ensure that you're using a sharp, appropriately sized needle designed for embroidery.
  2. Gathering necessary tools and materials: Assemble all the tools and materials you'll need, such as embroidery thread, embroidery hoops, scissors, and a good light source. Having everything within arm's reach will save you time and effort.
  3. Setting up a clean and organized workspace: A tidy workspace is essential for a smooth workflow. Ensure that your work area is clean and well-organized. This not only improves efficiency but also helps prevent damage to your materials and equipment.
  4. Position your machine ergonomically: Adjust the height and angle of your embroidery machine to suit your working posture. Proper ergonomics can reduce strain during long embroidery sessions.
  5. Test your machine: Before starting your embroidery project, run some test stitches on scrap fabric to ensure that your machine is set up correctly, and everything is in working order.

Selecting the Right Design

When choosing an embroidery design for embroidery on polyester project, there are several factors to consider. Here's how to make the best selection:

  1. Choose or create a suitable embroidery design: You can either select a pre-made embroidery design or create one from scratch. When selecting a design, consider its complexity, size, and the visual impact it will have on your polyester item.
  2. Considering design size and complexity: Think about the size of your polyester fabric and how the design will fit. Intricate designs might be challenging on smaller items, while larger pieces can accommodate more detailed patterns.
  3. How to digitize your design for polyester: If you're creating your design, it needs to be digitized into a format your embroidery machine can understand. You can use specialized software to digitize your design, ensuring it translates well onto polyester.
  4. Think about thread colors: The choice of thread colors can significantly impact the final look of your embroidered design. Consider the color scheme of your polyester fabric and select thread colors that complement it.
  5. Placement and alignment: Before you start embroidering, think about where you want the design to be placed on your polyester item. Ensure it's centered, aligned, and at the right height or width to achieve the desired aesthetic.

Digitizing Your Design for Polyester Embroidery

Moving on, you need to get your design digitized for your embroidery on polyester project. Digitizing your design is the art of converting your creative concept into a language that your embroidery machine can understand. Let's break it down how you can master the art:

  1. Select digitizing software: Begin by choosing reliable digitizing software. Popular options include Embird, Wilcom, and Hatch. This software serves as your canvas for creating machine-readable embroidery data.
  2. Import or create your design: If you have a pre-existing design, you can import it into the digitizing software. For those with a blank canvas, you can draw or trace your design directly within the software.
  3. Choose your stitch types: Within the software, you will specify the types of stitches to be used in your design. These include satin, fill, and running stitches, each affecting the texture and look of the final embroidery.
  4. Adjust stitch density: The stitch density defines how closely the stitches are placed in your design. Fine-tune this parameter to achieve the desired coverage on your polyester fabric.
  5. Select thread colors: Match the thread colors in your design with the color scheme of your polyester fabric. Ensure you have the correct thread codes or swatches for precise color reproduction.
  6. Consider underlay stitches: Underlay stitches are the foundation for the top layer of stitches. Configuring these properly ensures stability and prevents fabric distortion during embroidery.
  7. Fine-tune your design: Make necessary adjustments, like resizing or repositioning elements, to ensure your design fits well on your chosen polyester fabric.
  8. Save in the correct format: Save your digitized design in the format compatible with your specific embroidery machine. Common formats include .PES, .DST, and .EXP.

Preparing the Polyester Fabric

Well, before you can move on with any embroidery on polyester project, preparing the polyester fabric is utmost important. Remember, polyester is a special fabric and you need to prepare it the right way to achieve best embroidery results. Here's how to do it:

  1. Washing and prepping the fabric: Start by washing your polyester fabric. Use a mild detergent and cold water to remove any dirt, oils, or sizing. This step prevents potential fabric distortion during the embroidery process.
  2. Hooping techniques for polyester: Use the appropriate hooping technique. Polyester is sensitive to heat, so avoid stretching or overheating the fabric when hooping. Make sure the fabric is taut, not too tight, or too loose in the hoop.
  3. Stabilizers and their role in polyester embroidery: Stabilizers are your best friend when embroidering on polyester fabric. They provide essential support to prevent puckering, distortion, and ensure clean embroidery. Choose the right type of stabilizer for your project, whether it's tear-away, cut-away, or wash-away.
  4. Test stitching: Before you start your main embroidery project, perform a test stitch on a piece of the same polyester fabric to ensure the hooping and stabilizers are correctly set up, and your machine is functioning smoothly.
  5. Position your design: Decide where you want your design to be embroidered on the polyester fabric. Mark the spot carefully to ensure precise placement.

Thread and Needle Selection

The success of your embroidery on polyester fabric project largely depends on your choice of thread and needle. Here's what you need to know:

Selecting the Right Thread:

  1. Polyester embroidery thread: Opt for polyester embroidery thread to match the fabric. Polyester thread is a perfect choice for polyester fabric as it offers durability and colorfastness.
  2. Thread weight: Consider the weight of the thread. A 40-weight polyester thread is a versatile choice suitable for various embroidery projects on polyester fabric.
  3. Matching colors: Choose thread colors that complement your design and polyester fabric. Ensure they match seamlessly for a professional finish.

Choosing the Appropriate Needle:

  1. Needle type: Use a sharp, fine needle designed specifically for embroidery on polyester fabric. Needles with a ballpoint tip can minimize the risk of fabric pulls or damage.
  2. Needle size: Select the needle size based on the weight and density of the fabric. A size 75/11 or 80/12 needle is a good starting point for most polyester embroidery projects.
  3. Needle change: Replace your needle regularly to maintain optimal performance. A worn or damaged needle can lead to skipped stitches or fabric snags.

Machine Settings

To make the most out of your polyester embroidery project, here are some essential machine settings and adjustments to consider:

Machine Speed and Stitch Length:

  1. Adjusting machine speed: Polyester fabric, being more delicate than some other materials, may require slower stitching speeds. Start at a moderate speed, and gradually increase it as you become more comfortable with the fabric's response.
  2. Choosing the right stitch length: The stitch length can affect the overall look of your design. Shorter stitches create denser embroidery, while longer stitches offer a more textured appearance. Experiment with different lengths to achieve the desired effect on polyester.

Stitch Types:

  1. Selecting appropriate stitch types: Your embroidery machine may offer various stitch options. Choose the stitch type that best complements your design. For polyester fabric, satin stitches are often a good choice for a polished, smooth finish.
  2. Satin stitch angle: If your design includes satin stitches, you can adjust the angle to achieve a different look. Experiment with different angles to see what works best for your project.

Test Stitching and Making Adjustments:

  1. Test stitching on scrap fabric: Before embroidering on your actual polyester project, it's wise to perform test stitches on a piece of scrap polyester fabric. This helps you fine-tune settings, tension, and observe how your machine interacts with the fabric.
  2. Tension adjustment: Pay close attention to thread tension during test stitches. Polyester fabric may require different tension settings compared to other materials. Make adjustments as needed to avoid puckering or loose stitches.

Hooping Techniques

Hooping is more than just securing your fabric in an embroidery hoop; it's about achieving the right tension and alignment.

Here's what you need to know about hooping techniques for polyester fabric:

  1. Choose the correct hoop size: Select an embroidery hoop that matches the size of your design and polyester fabric. The hoop should hold the fabric securely without excessive stretching or distortion.
  2. Hooping tools: Invest in hooping aids like adhesive stabilizers, hoop grids, and alignment templates. These tools make hooping more precise and less prone to errors.
  3. Stabilize your fabric: Before hooping, apply the appropriate stabilizer to the back of your polyester fabric. The choice of stabilizer (tear-away, cut-away, or wash-away) depends on the design complexity and fabric type.
  4. Lay the fabric flat: Smooth out your polyester fabric within the hoop, ensuring there are no wrinkles or folds. Proper alignment is crucial for accurate embroidery.
  5. Secure the hoop: Gently press the top hoop onto the bottom hoop, ensuring the fabric is taut but not overly stretched. Tighten the hoop screw just enough to hold everything in place.
  6. Check fabric tension: To gauge the tension, gently tap the fabric with your fingertip. It should produce a drum-like sound, indicating it's adequately taut.
  7. Mark the center: Use a water-soluble fabric marker or tailor's chalk to mark the center of your embroidery design on the fabric. This helps with precise placement.
  8. Align with machine: Place the hooped fabric in your embroidery machine, ensuring that it lines up with the machine's alignment marks. Check the center marks on both the hoop and the machine for accuracy.

Finishing and Care

Embroidering on polyester fabric is a skill worth mastering. Now, as you near the completion of your project, it's important to pay attention to these final steps:

1. Trim Threads: Carefully trim any loose threads on the front and back of your embroidery. Precision in this step adds to the professional finish of your project.

2. Inspect for Quality: Examine your embroidery for any missed stitches, thread breaks, or other imperfections. Make any necessary repairs to ensure your project meets your quality standards.

3. Remove from Hoop: Gently remove your embroidered fabric from the hoop. Take care not to stretch or distort the fabric during this process.

4. Clean the Fabric: If your polyester fabric is washable, consider giving it a gentle hand wash to remove any stabilizer residue. Ensure that the detergent is mild and water temperature is cool.

5. Allow to Dry: After washing, let the fabric air dry. Avoid using high heat or direct sunlight, as polyester can be sensitive to extreme temperatures.

6. Iron with Caution: If ironing is required, use a low heat setting, and iron on the reverse side or with a pressing cloth to avoid direct contact with the embroidered design.

7. Store Carefully: Store your finished embroidery project in a cool, dry place, away from direct sunlight. If possible, place it in a protective cover or frame it to preserve its quality.

8. Show Off Your Work: Whether you're embroidering for personal satisfaction or business purposes, displaying your finished pieces can be a source of pride and motivation.


In the world of embroidery, polyester fabric offers both a canvas and a challenge. With the right knowledge and a bit of practice, you can create stunning designs that stand the test of time. So, grab your hoop, thread your needle, and let your creativity flow!

And speaking of creativity, at Genius Digitizing, we're all about turning your ideas into vibrant, professional embroidery. Whether it's polyester or any other fabric, our digitizing experts are here to bring your designs to life.