This study aims to investigate the influence of embroidery design parameters on aesthetic perception and process reliability across different textile fabrics. It examines how stitch density, fabric structure and thread type interact to affect perceptual attributes (appeal, quality, clarity and comfort) in conjunction with production-related performance indicators, that is, yarn breakage and operational stability.
Polyester and viscose embroidery threads were assessed on textile fabrics with varied fiber compositions and structures. A single-color motif combining run, satin, zigzag, coil and triple-run stitches was produced at three stitch-density levels: A (low), B (moderate) and C (high), yielding 54 samples using Wilcom software and embroidered under controlled conditions on a multi-head industrial embroidery machine. Perceptual attributes were assessed through structured subjective evaluation in a controlled assessment involving 100 female participants (24–27 years), while process reliability was quantified using yarn breakage frequency and production time. Statistical analysis was conducted to determine the significance of main and interaction effects.
The results indicated that stitch density is the most influential parameter affecting both esthetic perception and process reliability. Moderate stitch density (Design B) produced the highest ratings for appeal, quality and clarity, while higher density (Design C) improved comfort and significantly reduced yarn breakage. Viscose thread enhanced visual attributes due to its luster, whereas polyester thread demonstrated superior process reliability owing to its higher tensile strength and abrasion resistance. Fabric structure significantly moderated these effects, with stable and smoother fabrics yielding improved embroidery performance. A clear trade-off between esthetic quality and breakage risk was observed.
The study is limited to selected fabric compositions, stitch densities and thread types under controlled laboratory conditions. Perceptual evaluation was limited to 100 female participants aged 24–27 years and results reflected relative tendencies within this demographic. Subjective attributes were assessed using structured Likert scales with acceptable reliability. No physical testing of threads or embroidered structures was performed. Future research may extend this framework by incorporating additional embroidery parameters (e.g. stitch types, underlay configurations) and objective fabric hand measurements. Nonetheless, the findings contributed to a deeper understanding of the material–design–process interaction in embroidery systems.
The study provides a decision-support framework for optimizing embroidery parameters in industrial settings. Manufacturers can utilize the findings to balance visual quality and production efficiency by selecting appropriate combinations of stitch density, thread type and fabric structure, thus reducing machine downtime and improving product consistency.
By enhancing production efficiency and product durability, the study supports sustainable manufacturing practices in the textile and apparel industry. Improved parameter optimization can reduce material waste, energy consumption and rework, contributing to more responsible and resource-efficient production systems.
To the best of the authors’ knowledge, this study is among the first to integrate perceptual evaluation with process reliability metrics within a unified experimental framework for machine embroidery. It advances existing knowledge by establishing empirical relationships between design parameters, material properties and production performance and by translating these findings into a practical decision-making tool for embroidery parameter selection.
