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Screen-Printed vs Felt Applique Pennants

May 28, 2026 · 6 min read

Three decoration methods cover almost every custom felt pennant: screen printing, sewn-on die-cut felt applique, and embroidery. They look different, they cost different amounts, and they age differently. Choosing well is the difference between a pennant that reads as a giveaway and one that reads as a keepsake.

This guide compares the three on cost, look, durability and best use, then gives you a side-by-side table. Heat-pressed twill and chenille sit alongside these as specialty options, but the core decision is usually print versus applique versus embroidery.

Screen printing

Screen printing lays ink directly onto the felt. It handles detailed logos, multiple colors and gradients that stitching cannot, and it is the most affordable method at higher quantities because the setup cost spreads across the run. The trade-off is a flatter, printed look and ink that can soften over many years of handling. For giveaways, retail stock and detailed mascot art, screen print is usually the right call.

Sewn felt applique

Applique uses die-cut felt letters and shapes sewn onto the pennant body. This is the classic varsity look, with real dimension and layered color you can feel. It costs more than printing because each piece is cut and stitched, and very fine detail is limited by what can be cut cleanly from felt. For team names, single initials and a premium feel, applique is hard to beat.

Embroidery

Embroidery stitches thread directly into the felt. It is the most durable decoration, holds crisp small text and crests, and carries a heritage look that suits alumni and reunion pieces. It is the most expensive per unit and large solid-color fill areas are slow to stitch, so it is best reserved for crests, dates and shorter text rather than full-bleed designs.

Side-by-side comparison

Combining methods

The methods are not exclusive. A common build is screen-printed background art with an applique letter and an embroidered year, which balances cost against a premium finish. Add a sewn band header with grommets, ribbon streamers or a dowel and you have a display piece rather than a flat handout.

What it costs

Across our standard sizes, per-pennant pricing runs roughly $4 to $16 depending on size and method, with screen print at the low end and full embroidery at the high end. Our minimum is 25 pennants and a free mockup arrives within 24 to 48 hours, so you can see your art rendered in each method before deciding.

Choosing for your order

Match the method to the job. Screen print for large runs and detailed art, felt applique for a premium varsity look, embroidery for crests and text that should last for decades. We can also combine methods on a single pennant. Our minimum is 25, mockups are free within 24 to 48 hours, and per-pennant pricing runs roughly $4 to $16 depending on size and method.

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