There is nothing more frustrating than watching your machine chew up a polo shirt because the text was too small.

When letters get smaller than 5mm (0.2 inches) the standard rules of digitizing stop working. If you use the same settings for a 4mm letter as you do for a 2-inch logo you will get a bird nest or unreadable blobs.

Here is the "Small Text Formula" we use to keep lettering crisp even at 3mm height.

1. Kill the Underlay

This is the #1 mistake. On big letters we use Edge Run or Zig-Zag underlay to stabilize the fabric. On small text there is no room for that. An edge run will poke out of the side and a zig-zag will make the column too thick.

• The Fix: Use Center Run underlay only. If the text is under 4mm turn off underlay completely.

2. Lighten the Density

Standard density is usually 0.40mm. For small text that is too tight. The needle penetrations are too close together and they will cut the fabric.

• The Fix: Open your density to 0.50mm or 0.55mm. You need to let the fabric breathe.

3. Exaggerate the Openings

Thread has thickness. On a screen a letter "A" or "e" looks fine. On fabric the thread spreads and closes up the holes (we call this the "bridge").

• The Fix: Manually pull the holes open in your software. Make the opening of the "e" and "a" wider than you think looks normal. It will close up when stitched.

4. Change Your Needle

You cannot stitch a fine detail with a crowbar. A standard 75/11 needle is too fat for 4mm text.

• The Fix: Switch to a 60/8 or 65/9 needle. This smaller needle makes smaller holes and keeps the text sharp.

5. Use 60 Weight Thread (Optional)

If you are doing high-end corporate logos buy a spool of 60wt thread (thinner than standard 40wt). It allows for 25% more detail in the same amount of space.