Promotional Product Decoration Techniques: The Ultimate Guide

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by | Nov 18, 2024

Promotional Product Decoration Techniques: The Ultimate Guide

Promotional merchandise is your brand’s canvas, and there are endless ways to bring your logo or design to life. But with so many options, how do you know which method is the perfect match for your vision?

That’s where this ultimate guide comes in.

We’ll break down the pros and cons of popular decoration techniques, making it easier than ever to choose the one that fits your brand and your budget. Let’s dive in!

Why Decoration Of Your Logo Matters

  • Creates instant visual impact by capturing attention and sparking curiosity about your brand
  • Strengthens brand identity through consistent use of logos, colours, and designs
  • Enhances perceived value by elevating the appeal of your merchandise
  • Drives brand recall as standout decorations encourage people to keep and use the product
  • Fosters emotional connection by aligning designs with your audience’s tastes and preferences

Screen Printing

Screen printing is a popular method where ink is pressed through a stencilled mesh screen directly onto the product. It’s ideal for bold and vibrant designs on various materials.

Popular on: T-shirts, tote bags, umbrellas, notebooks, towels and other flat products.

Pros

  • Large decoration area on flat products
  • Cost effective for high-volume orders
  • Close PMS colour matching
  • Fluorescent and metallic inks available on some textile products
  • Most products can be printed with close multi colour registration (perfectly aligning multiple colours). With printing of up to 5 colours

Cons

  • Close PMS colour matching is more difficult on darker products and may require a base coat of white for colour accuracy (additional cost)
  • Unable to print variable data (such as individual names)
  • Each colour requires separate setup time and materials (incurring additional costs)

Limitations

  • Artwork must be supplied in vector format for optimum quality
  • Fine details (such as text 1mm or less) may infill
  • Difficult to achieve colour gradients

Pad Printing

Pad printing uses a silicone pad to transfer ink from an etched plate onto the product, making it perfect for printing on irregular or curved surfaces with fine details.

Popular on: Pens, keyrings, mugs, USB drives, golf balls and other small or curved items.

Pros

  • Can print curved or uneven surface products
  • Print is high detail with details as fine as 0.4mm.
  • Close PMS matches on white or light coloured objects
  • Metallic gold or silver inks available
  • Many products can be printed in up to 6 colours with tight multi-colour registration (perfectly aligning multiple colours)

Cons

  • Unable to print variable data such as individual naming
  • Limited maximum decoration area
  • Darker products may require a base white print for colour accuracy
  • Each colour requires it’s own setup

Limitations

  • Artwork must be supplied in vector format for optimum quality
  • Minimum text size is typically 5pt
  • Neon/Fluorescent colours are not available
  • While fine details can be achieved

Digital Heat Transfers

Digital transfers involve printing a design onto transfer paper, which is then heat-pressed onto the product. This method is great for full-colour, complex images. It can have many names such as Supacolour, Colourflex, Power Print etc.

Popular on: Bags, t-shirts, jackets, backpacks, caps.

Pros

  • Vibrant unlimited colours with gradients available
  • Durable and flexible
  • Only one setup is required
  • Variable data available on some options
  • Fast production times typically

Cons

  • A think clear line of glue can sometimes be seen around the edge of images
  • Pricing is usually dependent upon the print size (larger prints cost more)

Limitations

  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality
  • Requires heat for application so may not be compatible on some products
  • Minimum detail advised at around 1mm

Laser Engraving

Laser engraving uses a laser to remove material from the product’s surface, creating a precise and permanent design that’s ideal for metals and wooden products.

Popular on: Pens, drink bottles, glassware, cheeseboards and other metal/wooden items.

Pros

  • Premium finish with high value perception
  • Permanently apart of product surface
  • Large branding areas available on curved products
  • Can decorate variable data (such as names) on select products

Cons

  • On wooden surfaces like bamboo the branding can vary based on the wood grain
  • Cannot choose the finish colour (based on material colour)
  • Fine detail can get lost in smaller items such as pens

Limitations

  • Typically only available on certain metal/glass/wooden products
  • Artwork must be supplied in vector format for optimum quality

Embroidery

Embroidery stitches thread directly into the fabric to recreate the design, offering a durable and high-quality decoration ideal for apparel and textiles.

Popular on: Caps, polo shirts, jackets, backpacks, towels.

Pros

  • High perceived value
  • Durable and long-lasting
  • Adds texture and dimension
  • Only one setup charge applies
  • Great for caps, apparel and textiles

Cons

  • Only approximate PMS colour matches are possible. Limited by available thread colours
  • Usually unable to brand variable data (individual naming)
  • Is usually more expensive than printing (based on stitch count required)
  • Not ideal for large decoration areas

Limitations

  • Artwork must be supplied in vector format for embroidery digitisation
  • It’s recommended avoiding finer details and having fonts any less than approximately 5mm

Digital Printing

Digital printing is used for printing on media like paper, vinyl, and magnetic materials, making it ideal for creating labels, badges, and fridge magnets. This process utilizes CMYK values to produce full colour images.

Popular on: Notepads, sticky notes, coasters, button badges and other paper products.

Pros

  • Unlimited colours and complex images including gradients is possible
  • Only one setup charge
  • Usually edge to edge printing
  • Usually cost effective

Cons

  • Limited to certain materials such as paper

Limitations

  • White print cannot be produced on kraft, clear, silver or gold stock
  • Cannot print on dark coloured substrates as white ink cannot be printed under artwork
  • A 3mm bleed should be added to the artwork
  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality

Debossing/Embossing

Debossing and embossing create a recessed or raised design on the product’s surface by pressing it with a metal die, adding a tactile and elegant effect.

Popular on: Notebooks, compendiums, travel wallets, silicone products.

Pros

  • High perceived value
  • Branding permanently becomes part of the product
  • Certain products can create a two tone finish
  • Uses no inks or additional materials

Cons

  • Unable to brand variable data such as individual naming
  • Usually has a higher setup cost
  • Only available on certain product materials

Limitations

  • Minimum line thickness 0.4mm
  • Artwork must be supplied in vector format for optimum quality

Digital Labels

Digital labels are printed stickers that are applied to products, allowing for high-quality, full-colour images with variable data like barcodes.

Popular on: Confectionery, sunscreen, hand sanitiser.

Pros

  • Can print unlimited full colours
  • Cost effective
  • Can be cut to custom shapes and printed edge to edge
  • Only one setup charge required

Cons

  • Not as durable as other decoration options. Typically recommended for packaging or giveaway items
  • Not as high value perception as other decoration types

Limitations

  • White print sometimes cannot be produced on clear, silver or gold stock
  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality

Direct Digital Printing

Involves the transfer of ink directly from the print heads of an inkjet machine onto the product. Can be used to produce full colour and closely match spot colours.

Popular on: Notebooks, pens, power banks, stationery and other flat products with a hard surface.

Pros

  • Unlimited full colour printing
  • Variable data is available on select products
  • Large print area
  • Ideal for printing dark products as a base white layer can be applied

Cons

  • Decoration area is limited on curved surfaces
  • Sometimes large print areas can be more expensive

Limitations

  • A 3mm bleed must be added to some products
  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality

Sublimation Printing

Sublimation printing is a technique where heat transforms dye into gas, allowing it to bond directly to materials like polyester or polymer-coated items, skipping the liquid phase. This process creates vibrant, long-lasting prints as the dye solidifies into the material itself.

Popular on: Towels, apparel, coffee mugs, bags.

Pros

  • Dye is printed inside the material itself (won’t ever rub off)
  • Large decoration area (edge to edge) available on most products
  • Can print unlimited full colour
  • Variable data printing available on some products
  • Only one setup cost required

Cons

  • Only available on certain products/materials with white surfaces
  • Some colours cannot be reproduced well such as white, metallic and some fluorescent colours.

Limitations

  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality
  • A bleed area must be added to the artwork if it bleeds off the product

Rotary Digital Printing

Involves the transfer of ink directly from the print heads of an inkjet machine onto the product. Can be used to produce full colour and closely match spot colours.

Popular on: Drink bottles, reusable coffee cups/tumblers.

Pros

  • Large decoration areas
  • Unlimited colours
  • Only one setup charge is required
  • Vibrant print on all coloured products
  • Sometimes choice between matte or gloss finish

Cons

  • Usually more expensive than a rotary screen print
  • Limited production capacity resulting in longer production times

Limitations

  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality
  • Sometimes a small gap is required (cannot fully wrap around)

Rotary Screen Printing

Rotary Screen Printing involves pressing ink through a fine mesh screen onto the product using a squeegee. This technique is perfect for cylindrical objects, delivering sharp and consistent prints with high durability.

Popular on: Drink bottles, pens, coffee cups.

Pros

  • Large print area
  • Close PMS colour matches are possible on light/white products
  • Very cost effective
  • Metallic gold and silver colours available

Cons

  • Some products have a 1 colour limit due to colour registration
  • Unable to print variable data
  • Sometimes a base white coat is required to achieve colour accuracy on darker products (additional cost)
  • Fine details may infill

Limitations

  • Artwork must be supplied in vector format for optimum quality

Foil Printing

Foil Printing uses heat and pressure to apply metallic foil directly onto flat surfaces with modern digital foiling, eliminating the need for plates. The foil reflects the texture of the substrate, with variations in finish on soft-touch versus standard PU. Available colours include Gold, Silver, and Copper.

Popular on: Notebooks, gift boxes.

Pros

  • High value perception
  • Variable data (individual naming) is available
  • Flexible foil that also works on soft-cover notebooks

Cons

  • Detailed artwork can get lost when the surface is textured
  • Unable to brand fine details
  • Only available on limited products e.g. notebooks

Limitations

  • Artwork must be supplied in vector format for optimum quality
  • Minimum line thickness 1mm (textured) or 0.4mm (smooth)

Hot Stamping

Hot Stamping uses a heated metal plate to press an indented design onto the product surface, leaving a lasting impression. Ideal for materials like wood, it creates a durable, high-quality finish.

Popular on: Cheeseboards, chopping boards.

Pros

  • High value perception
  • Permanently apart of the product
  • Produces a nice finish

Cons

  • Unable to print variable data
  • Decoration result can vary product to product

Limitations

  • Minimum line thickness is 0.4mm
  • Artwork must be supplied in vector format for optimum quality

Imitation Etch Printing

Imitation Etch uses specialised ink applied through pad or screen printing to create an etched look on glass products.

Popular on: Wine glasses, beer glasses and other glassware.

Pros

  • High value perception and much more affordable than real etching
  • Can be decorated on curved surfaces

Cons

  • Unable to print variable data
  • Longer production times as a curing period is required

Limitations

  • Artwork must be supplied in vector format for optimum quality

Resin Coated Finish

This CMYK process prints artwork onto adhesive-backed vinyl, which is coated with a clear resin for a glossy finish. Once dried, the decal is applied to the product, forming a durable, permanent bond.

Popular on: Keyrings, lapel pins, name tags.

Pros

  • Full colour printing
  • Creates a 3D effect
  • Can be printed edge to edge
  • Only one setup cost is required

Cons

  • Not ideal for large print areas
  • Production time can take longer as the resin needs to be cured

Limitations

  • Vector or high resolution bitmap format required
  • A bleed area must be added to the artwork

Patches

Woven patches are crafted with tightly woven threads for sharp details and vibrant colours, then embroidered onto products for a durable, professional finish. Similar methods include Supasub for full-colour embroidered-style badges, Supaetch for laser-etched suede patches, and Supaflex for high-detail logos with matte or gloss finishes.

Popular on: Caps, jackets, backpacks, sports bags, uniforms.

Pros

  • Similar value perception to an embroidery
  • Economic price
  • Many patch options available including engraved, embroidered and sublimated styles
  • Fine detail and an unlimited number of colours can be achieved

Cons

  • Not ideal for lightweight fabrics
  • Limited flexibility

Limitations

  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality

Die Casting/Die Striking

Die Casting/Die Striking involves creating custom designs by pressing metal into a mould or striking it with a die. Commonly used for enamel pins, this method produces precise, durable designs with intricate details and a polished finish.

Popular on: Lapel pins, belt buckles, medals, coins.

Pros

  • Durable and long lasting design
  • Capable of intricate details, making it ideal for custom logos or text
  • Offers a premium, polished look that enhances perceived value

Cons

  • Requires longer production times
  • May have higher initial setup costs
  • Best suited for small items

Limitations

  • Artwork must be supplied in vector format or high resolution bitmap for optimum quality
  • Limited to metal products

Summing Up

Decorations are more than just a finishing touch—they’re the key to transforming promotional products into powerful brand ambassadors. Whether it’s a perfectly embroidered logo on a sleek polo or a vibrant print on a tote bag, every detail matters.

By focusing on high-quality, thoughtful decorations, your brand can leave a lasting impression that builds trust, loyalty, and recognition.

Ready to make your mark? Let Promotion Products help you design promotional merchandise that not only stands out but also speaks volumes about your brand’s identity and values.