Screen printers, we all know the struggle—test prints, misprints, and fabric scraps piling up with nowhere to go. Instead of tossing them, what if you could turn those leftovers into one-of-a-kind, premium apparel? That’s where the appliqué technique comes in!
In this video, we’ll show you how to take your screen printing waste and transform it into high-end embroidered designs, adding texture, dimension, and sustainability to your products. Whether you’re running a custom shop or just love experimenting, this is a game-changing way to reduce waste and boost your creativity.
What is Appliqué Embroidery?
Appliqué is an embroidery technique where fabric pieces are stitched onto a base garment to create designs. Instead of filling large areas with thousands of stitches, you can use pre-cut fabric pieces—saving thread, time, and adding a unique aesthetic to your work.
This method isn’t just about efficiency; it’s also a creative way to upcycle old prints, repurpose scraps, and make garments that stand out. By combining screen printing and embroidery, you’re blending two premium techniques into one stylish final product.
RELATED: HOW EMBROIDERY CAN TAKE YOUR SCREEN PRINTING BUSINESS TO THE NEXT LEVEL
Step 1: Cutting Your Appliqué Pieces
The first step in appliqué is cutting out your fabric pieces. You can do this in two main ways:
1. Scissors (Simple & DIY)
If you’re working on a one-off project or experimenting, a sharp pair of fabric scissors works just fine. Just be sure to cut clean edges for a polished look.
2. xTool Laser Cutter (For Precision & Speed)
For shops looking to scale up production, a laser cutter like the xTool is a game-changer. You can design your appliqué shapes digitally and have them cut perfectly every time, making it easier to align them with your embroidery.
🔥 Pro Tip: When using a laser cutter, create an embroidery file that matches your cut file to ensure perfect placement on your garment.
Step 2: Placing & Securing Your Appliqué
Once your fabric pieces are ready, they need to be placed on the garment before embroidery begins. Here’s how to do it right:
✅ Use a Positioning Stitch – Start by running a simple outline stitch to mark where your appliqué will go.
✅ Secure It Properly – For small pieces, you can place them directly. For larger pieces, use an embroidery-safe temporary spray adhesive to hold them in place.
✅ Avoid Machine Jams – Always trim excess thread before applying fabric and ensure the needle isn’t stuck in the garment before pausing.
Tip: Using the ZSK EPS (Easy Positioning System) can help create consistent hooping and placement.
Step 3: Embroidering Over the Appliqué
With the appliqué fabric secured, it’s time to stitch it down! Using your embroidery digitizing software, create a stitch pattern that locks the appliqué into place, usually with a satin stitch or decorative edge.
If you’re running a high-volume job, pre-cutting your appliqué pieces in bulk allows you to streamline production—just grab, place, and stitch!
Why Appliqué? Unique Looks & Sustainable Practices
This technique isn’t just practical—it’s also a huge selling point for eco-conscious customers. Today’s buyers love sustainable, handcrafted products, and appliqué embroidery lets you:
♻️ Reduce waste by repurposing screen printing scraps
🎨 Create one-of-a-kind, high-end designs
⚡ Speed up embroidery production by using fabric instead of heavy stitching
By offering appliqué designs, you’re adding value, sustainability, and creativity to your shop.
Final Thoughts: Ready to Upcycle?
Next time you have a misprint or extra fabric, don’t toss it—turn it into art! Appliqué embroidery is a perfect way to add texture, style, and sustainability to your screen printing shop.