Use lettering that has been digitised at the size you intend to stitch, because letters do not scale well in either direction.
Size limits. Most embroidery fonts have a stated minimum, commonly around 5 to 6 mm capital height for satin-stitched letters. Below that the satin columns become too narrow to form and the letters fill in solid. Above the stated maximum, the satin stitches become long and loose enough to snag. Built-in machine fonts handle a range because they are generated rather than fixed.
Choose the style for the size. Small text wants a plain block font or a simple outline style. Script fonts with fine connections need to be larger. Heavily decorated fonts fail first at small sizes.
Topping matters more than usual. On any knit, towel or textured fabric, a water-soluble film over the surface is what keeps thin letters sitting on top of the fabric rather than sinking between the loops.
Use a finer thread and needle for small text — 60 weight thread and a 65/9 or 70/10 needle give noticeably cleaner small letters than 40 weight on a 75/11.
Slow the machine down on lettering. Direction changes are constant and speed causes both breakage and rounded corners.
Check the spelling on screen and again on the trace, and check the position of the baseline against a seam or an edge. There is no correcting a name after it is stitched.
Stitch a test of the exact name at the exact size on the exact fabric.
Questions people actually ask
How small can lettering go?
Roughly 5 to 6 mm capital height for satin stitch, and smaller only with fonts digitised specifically for micro text, a fine thread and a small needle.
My letters have rounded corners.
Speed, mostly. Slow down and check the design is not being scaled from a much larger original.
Last reviewed 2026-08-11