Embroidery density: what it is and how to get it right
Density is the distance between one row of stitches and the next. It decides whether the embroidery covers the fabric well or turns stiff, heavy and puckered.
How it is measured
In embroidery software, density shows as the spacing between rows, in millimeters. The smaller the spacing, the more stitches and the more coverage. On regular fabric, fill usually sits near 0.4 mm between rows, and the digitizer adjusts from there.
Too much density
Embroidery as stiff as cardboard, fabric puckered around it, broken needles and snapping thread. It also uses more thread and machine time without improving anything.
Too little density
The fabric shows between the stitches, especially with light thread on dark fabric. The embroidery looks patchy.
It changes with fabric and size
Thick and fluffy fabrics accept and need more coverage. Thin knits need less. When you enlarge or shrink a stock design, the density changes too, which is why heavy resizing ruins embroidery.