Custom Sweatshirts & Embroidered Sweatshirts – The Complete Guide for Brands in 2025

Why Sweatshirts Are More Than Just Basics

Few garments tell the story of modern fashion better than the sweatshirt. Once a simple piece of athletic wear, the sweatshirt has become one of the most versatile staples in streetwear, athleisure, luxury fashion, and corporate branding.

Today, whether it’s a custom sweatshirt for a startup streetwear brand, an embroidered sweatshirt for a university, or a limited-edition personalised embroidered hoodie designed by an influencer, the sweatshirt is no longer just an afterthought — it’s a centerpiece. Custom sweatshirts are not only stylish but also make a thoughtful gift for birthdays, holidays, or corporate events.

At Athleisurebasics, we see this every day. Our network of factories in Portugal produces thousands of sweatshirts each year, from heavyweight oversized hoodies for streetwear brands in Los Angeles to embroidered corporate sweats for tech companies in Berlin. And what unites all these projects is the fact that sweatshirts — simple, durable, endlessly customizable — are the ultimate canvas for creativity.

This article is a complete guide to everything you need to know about custom sweatshirts and embroidered sweatshirts in 2025. We’ll cover the different fits, fabrics, production methods, embroidery options, and why Portugal has become the go-to hub for brands that want both quality and flexibility.

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1. Why Custom Sweatshirts Matter in 2025

The sweatshirt isn’t just “another item” in a collection. It’s the piece people wear most often. For many brands, it’s the single product that creates recognition. Finding the right custom sweatshirt is crucial for business success and establishing a strong brand identity.

The Role of the Custom Sweatshirt

• Streetwear Identity: Think of Supreme’s box logo crewnecks or Fear of God’s oversized hoodies. One sweatshirt design can define a brand.

• Corporate Branding: Companies invest in embroidered sweatshirts for uniforms and teamwear because they balance comfort and professionalism.

• Merchandise & Events: Festivals, universities, and clubs rely on personalized sweats as part of their identity.

• Startups: Many first-time fashion entrepreneurs begin with sweatshirts because they’re versatile and low-risk.

• Cropped: Popular in women’s athleisure, especially among ladies and women. Cropped sweatshirts are a favorite in women’s collections, and shirts are also a versatile option included in many apparel lines.

A well-made, well-embroidered sweatshirt is a long-lasting walking billboard — worn hundreds of times by the consumer. That makes it one of the highest-ROI products for any brand.

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2. Fabrics and Fits: The Foundation of Quality

At AB, we emphasize that embroidery or print can only shine if the base garment is premium. Sweatshirts vary dramatically in quality, and brands that cut corners at this stage struggle long-term. Selecting high quality materials and the right material is essential for ensuring durability, comfort, and a superior finished product.

Common Fabric Options

• Heavyweight Cotton Fleece (440 GSM) – Our bestseller for oversized hoodies and premium embroidered sweatshirts. This is the “luxury streetwear” weight.

• Midweight Cotton Fleece (320 GSM) – A lighter alternative that works well for everyday sweatshirts.

• Organic Cotton – OEKO-TEX® certified, sustainable, soft to the touch, and increasingly demanded by consumers.

• Blends with Recycled Polyester – Add durability, reduce shrinkage, and meet eco-friendly production standards. Blue is one of the most popular color choices for custom sweatshirts, available in a range of shades from light blue to classic navy.

• 50/50 Cotton/Polyester Blend – Commonly chosen for its durability and comfort, making it a versatile option for custom sweatshirts.

Fit Options

• Classic Fit: Timeless, comfortable, slightly tailored.

• Oversized Fit: Dropped shoulders, wide body — the global streetwear standard in 2025.

• Cropped: Popular in women’s athleisure.

• Boxy Fit: Shorter body, wider chest — a newer streetwear trend.

• Youth Sizes: Many brands now offer youth-sized sweatshirts to cater to younger customers, schools, and family-oriented collections.

When customers ask “How do I make sure my embroidered sweatshirt looks premium?” our answer is simple: start with a high-quality blank. A great fabric weight and fit elevate the embroidery immediately.

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3. Embroidery: Adding Dimension and Durability

One of the most popular requests we receive is for embroidered sweatshirts. Embroidery instantly changes the feel of a garment. Custom embroidered sweatshirts can look fantastic and stylish, elevating the overall appeal and making them perfect for those seeking both fashion and comfort.

Why Brands Choose Embroidery

• Longevity – Unlike prints that may crack or fade, embroidery lasts and is considered more durable than screen printing for custom sweatshirts.

• Premium Finish – Stitched logos or artwork feel luxurious and textured.

• Cozy & Warm – Embroidered sweatshirts are made from cozy, warm materials, making them perfect for comfort and style in colder weather.

• Versatility – Works for minimalist branding (small chest logo) or bold statements (oversized back embroidery).

Embroidery Techniques

• Flat Embroidery: Clean, simple, ideal for text or logos.

• 3D Puff Embroidery: Raised effect — popular in streetwear and sportswear.

• Chain Stitch: Retro, vintage vibe.

• Appliqué: Fabric patches stitched onto the sweatshirt.

Where to Place Embroidery

• Chest (left or center) — This is a popular spot for a company's logo, especially for team uniforms and promotional apparel.

• Sleeve embroidery (increasingly popular for logos)

• Back embroidery

• Hood embroidery

A client once asked us how to embroider a sweatshirt themselves. While DIY embroidery kits exist, most professional brands use industrial embroidery machines. At AB, every embroidered sweatshirt goes through digitizing (converting the artwork into a stitch file), multiple sampling rounds, and final quality checks.

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4. Personalized Sweats: The Age of Customization

If 2015 was the decade of mass-produced fast fashion, 2025 is the era of personalization. Consumers want items that feel unique to them.

The sweatshirt is no longer just a “basic” — it’s a story piece. Personalized sweatshirts and custom hoodies also make excellent gifts for special occasions like Mother's Day, Christmas, or team celebrations, offering thoughtful and customizable options for anyone looking for unique presents.

What Personalization Means Today

• Individual Names or Initials embroidered onto team sweats.

• Personalised embroidered hoodies created for clubs, events, or influencers.

• Custom slogans on sleeves or backs.

• Pantone-matched fabrics for brand exclusivity (cotton only).

Even corporations now order personalized sweats for their employees — not just with the company logo, but with the employee’s initials or role stitched in. It creates a sense of belonging and pride.

At AB, we’ve seen this personalization trend grow across streetwear startups, university merch, and luxury capsule collections. The sweatshirt is no longer just a “basic” — it’s a story piece.

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5. Printing vs. Embroidery: Which Is Right for You?

Many brands ask: “Should I print or embroider my sweatshirts?” Printed designs, such as those created through screen printing, offer a wide range of customization options for applying artwork to different areas of the sweatshirt. Direct-to-Garment (DTG) printing is another option, where designs are applied directly onto the fabric using a specialized inkjet printer, offering high detail and vibrant colors.

Printing Advantages

• Works for large, colorful designs.

• Lower cost at high volumes.

• Flexible across cotton and polyester.

Embroidery Advantages

• More durable, premium feel.

• Better for logos, minimalism, and high-end collections.

• Works best on heavyweight cotton.

The smartest brands often combine both: printing for bold graphics, embroidery for subtle branding.

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6. Browsing and Filtering Many Options for Custom Sweatshirts

When designing your custom sweatshirts, it’s important to browse many options to find the perfect fit, fabric, and style. Online platforms often allow you to filter choices by size, color, material, and decoration method to streamline your selection process.

Popular brands like Nike, Gildan, and Champion offer a wide range of customizable blanks that cater to different budgets and style preferences. Whether you want a heavyweight hoodie for durability or a lightweight crewneck for layering, filtering through available options helps you create exactly what your brand or team needs.

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7. Preparing Your Design: File Formats and Resolution

To ensure your custom embroidery or print looks sharp and professional, prepare your artwork in the right format. We recommend:

• File Formats: PNG, JPG, TIF, or PDF files are commonly accepted.

• Resolution: 300-350 dpi in RGB mode ensures crisp, vibrant designs.

Providing high-quality artwork helps avoid delays and guarantees your custom sweatshirts meet your expectations.

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8. Customer Care and How We Respond to Your Needs

At Athleisurebasics, we pride ourselves on responsive customer service. We work closely with clients throughout the design and production process, responding promptly to questions about fabric choices, sizing, embroidery placement, and order status.

Our team supports brands from the initial concept to delivery, ensuring your custom sweatshirts and embroidered hoodies meet your vision and quality standards. We also provide guidance on care instructions to help your customers maintain their apparel’s look and durability.

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9. Care and Maintenance of Custom & Embroidered Sweatshirts

To keep your custom embroidered sweatshirts and hoodies looking their best, it’s important to follow proper care and maintenance guidelines. High-quality custom apparel is an investment in your brand’s image, and with the right care, your sweatshirts and hoodies will remain vibrant, soft, and durable for years to come.

Washing, Drying, and Storing for Longevity

We recommend machine washing custom embroidered sweatshirts and hoodies in cold water to protect both the fabric and the embroidery. Avoid using bleach or fabric softeners, as these can break down the fibers and affect the quality of the stitching. For drying, opt for tumble drying on low heat or, even better, air drying to prevent shrinkage and maintain the garment’s shape. When storing your custom sweatshirts and hoodies, fold them neatly and keep them in a cool, dry place to avoid moisture buildup and potential damage to the materials.

Leading companies like Custom Ink and Custom Sweatshirts offer a wide range of custom apparel options, including crewneck sweatshirts, hoodies, and zip-hoodies made from cotton, polyester, and blends. Their user-friendly online design tools make it easy to create your own custom sweatshirts, with thousands of templates and the ability to add names, numbers, and logos. With expertise in custom embroidery and screen printing, these providers ensure your custom apparel meets the highest standards for quality, durability, and style—so your brand always looks its best, no matter the occasion.

By following these care tips and choosing reputable partners for your custom embroidery projects, you can ensure your custom embroidered sweatshirts and hoodies exceed expectations and continue to represent your brand with pride.

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10. Why Portugal Is the New Hub for Sweatshirt Manufacturing

For years, Asia dominated apparel production. But today, Portugal is the epicenter of quality sweatshirt manufacturing.

• Speed: Production and shipping to Europe and the US is faster than Asia. AB serves clients across America and ensures each order is carefully packaged for delivery.

Why Portugal?

• Low MOQs – AB starts production at just 60 pcs per style/color, perfect for startups.

• Premium quality – Portugal’s textile region is known for its craftsmanship.

• Sustainability – OEKO-TEX® certification, organic cotton, recycled fabrics.

• Speed – Production and shipping to Europe and the US is faster than Asia.

• Transparency – EU labor laws ensure ethical production.

At AB, we’ve positioned ourselves as one of Portugal’s largest manufacturing networks, helping brands launch with custom sweatshirts and embroidered hoodies at a fraction of the usual investment. Bulk ordering of custom sweatshirts often comes with discounts, making it an economical choice for growing brands.

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11. Case Studies: From Startups to Global Brands

Without naming clients, we can share patterns we’ve seen:

• A London-based startup launched with just 120 embroidered sweatshirts and hoodies. Their streamlined ordering process made it easy to launch their project quickly. Within six months, they scaled to 1,000+ pcs per drop.

• A US corporate client ordered embroidered sweats for their entire staff — personalized with names — creating a sense of identity and pride.

• A Berlin streetwear label focused entirely on oversized embroidered hoodies. Their brand identity was built around embroidery and heavyweight cotton.

In all these cases, the sweatshirt wasn’t just a garment. It was the foundation of the brand.

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12. Marketing with Custom Apparel

Custom apparel is a powerful tool for brands looking to stand out in a crowded marketplace. By designing custom embroidered hoodies and sweatshirts, businesses can create a unified and memorable brand image that resonates with both employees and customers. Whether you’re launching a new product, hosting an event, or simply looking to boost your brand’s visibility, custom apparel offers endless opportunities to showcase your unique style and message.

How Custom Sweatshirts Build Brand Awareness

Custom embroidered sweatshirts and hoodies are more than just comfortable clothing—they’re walking advertisements for your brand. By featuring your company’s logo, slogan, or signature artwork, you create a lasting impression every time someone wears your gear. This is especially effective at events, conferences, or trade shows, where a cohesive look can help your team stand out and attract attention. Custom embroidered sweatshirts can also be gifted to loyal customers or used as incentives for new clients, turning recipients into enthusiastic brand ambassadors who help spread your message far and wide.

Creative Campaigns and Merchandising Ideas

To maximize the impact of your custom apparel, consider launching creative campaigns that encourage customers to engage with your brand. For example, invite customers to share photos of themselves wearing your branded sweatshirts or hoodies on social media, using a unique hashtag to drive engagement and increase your reach. You can also offer limited-edition custom apparel as part of a loyalty program or special promotion, creating a sense of exclusivity and urgency that motivates customers to act quickly. By offering a variety of styles and customization options, you ensure there’s something for everyone—helping your brand connect with a wider audience and build lasting relationships.

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13. How to Order Custom & Embroidered Sweatshirts with AB

For brands looking to launch or expand, the process is simple:

1. Select Fit & Fabric – Choose between classic or oversized, 440 GSM or 320 GSM, organic or standard cotton.

2. Choose Decoration – Embroidery, print, or both.

3. Decide Quantity – Start as low as 60 pcs per style/color.

4. Prepare Artwork – Ensure your design is at an optimal resolution of 300-350 dpi in RGB mode for the best results.

5. Sampling – We produce samples for approval.

6. Production – Once approved, we move into full production.

7. Delivery – Shipped worldwide from Portugal.

And unlike many manufacturers, AB specializes in helping startups grow — supporting both personalized sweats for small batches and scalable production for established brands.

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14. The Future of Custom Sweatshirts in 2025 and Beyond

Looking ahead, sweatshirts will continue to evolve:

• Smarter fabrics with tech integration.

• Greater demand for sustainable materials.

• Customization at scale through digital tools. Brands can now design online using intuitive platforms, then let the manufacturer handle the rest—ensuring all their needs are covered from start to finish.

• Inclusivity – more unisex and body-diverse fits.

For brands, the sweatshirt is a product that will never go out of style. The only challenge is ensuring yours stands out through quality, embroidery, and storytelling.

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Conclusion

The sweatshirt is no longer a blank afterthought. It’s the centerpiece of collections, the canvas for personalization, and the symbol of brand identity.

From custom sweatshirts for startups, to embroidered sweatshirts for luxury drops, and personalised embroidered hoodies for events, the opportunities are endless.

At Athleisurebasics, we make it possible for brands worldwide to produce premium sweatshirts, hoodies, and personalized sweats in Portugal with low MOQs, sustainable fabrics, and luxury-level finishing.

👉 Ready to bring your sweatshirt idea to life? Shop now to discover our competitive price options and value for money—don’t wait to start your custom sweatshirt journey. Get a Quote and let’s build your next collection.

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Frequently Asked Questions (FAQ)

1. What is the typical minimum order quantity for custom sweatshirts?

At Athleisurebasics, we offer low minimum order quantities starting at just 60 pieces per style and color, making it ideal for startups and small brands.

2. How long does it take to receive custom embroidered sweatshirts after placing an order?

Production times vary depending on order size and customization complexity, but typically, it takes 4 to 6 weeks from artwork approval to delivery.

3. Can I mix different sizes and colors in one custom sweatshirt order?

Yes, most manufacturers, including Athleisurebasics, allow mixing sizes and colors within your order to accommodate your team's or customers' needs.

4. What fabric blend is best for durable and comfortable custom sweatshirts?

A 50/50 cotton/polyester blend is commonly recommended for its balance of durability, comfort, and ease of care, but heavyweight cotton fleece is preferred for premium embroidered sweatshirts.

5. How should I care for my custom embroidered sweatshirt to ensure longevity?

We recommend machine washing in cold water with like colors, avoiding bleach and fabric softeners, and tumble drying on low heat or air drying to protect the embroidery and fabric.

6. Is embroidery more durable than screen printing on sweatshirts?

Yes, embroidery is generally more durable and offers a premium textured finish that lasts longer without cracking or fading compared to screen printing.