Minimum Line Thickness
Thread has physical diameter. That diameter sets a hard lower limit on the finest detail a loom can reproduce — and no amount of production skill can work around it. The core rule: minimum stroke width of 0.5–0.8 mm at final label size, and text no smaller than 8 pt at final label size.
Why thread resolution limits exist
The physics of weaving
- Single thread diameter: ~0.15–0.25 mm. The smallest reproducible detail is roughly 2–3 thread widths, or ~0.4–0.6 mm at the finished label surface. A stroke thinner than 1 thread width will weave inconsistently or disappear.
- Damask vs standard resolution. Damask uses a finer thread count: minimum clean stroke ~0.4–0.5 mm vs 0.6–0.8 mm for standard satin. A useful improvement for designs near the threshold — but not a fix for heavily detailed artwork.
- At 30 mm label width, the minimum stroke in practice is ~0.5–0.7 mm, equivalent to ~1.5–2 pt when the document is set to physical dimensions.
What "at label size" means
- Your screen is not the label. A design open at 100% zoom is typically 2–4× the physical label dimensions. A stroke that looks substantial on screen can be well below the production minimum at actual size.
- How to check: set your document to the exact physical mm dimensions. View at 100%. This is what the label will look like — not the zoomed version. If elements look thin or small at that view, they need to be corrected.
- Print test: print at 100% on paper. If you can't read text or distinguish fine details at arm's length, the woven label will have the same problem — and weaving introduces further detail loss compared to printing on paper.
Common problem areas in label artwork
Fine borders and outlines
Thin outlines around logos look refined in print design but fall below weave resolution at label scale. Minimum border stroke: 0.5 mm at label size. See the logo labels guide for adapting brand marks.
Small tagline or secondary text
Website URLs, descriptors, slogans set at much smaller sizes than the brand name commonly fall below the readable threshold. Any text below ~2 mm cap height should be enlarged or removed. Consider a larger label if you need the text.
Narrow gaps between strokes
If two parallel lines are separated by less than 0.5 mm at label size, threads will visually fill the gap — the lines merge into one thick stroke. This affects nested borders, hatching patterns, and closely spaced letterforms.
High-contrast serif typefaces
Serif typefaces with very thin hairline serifs are problematic at small label sizes — the hairline strokes fall below weave resolution. Switch to a low-contrast serif or sans-serif, or set text larger and accept a wider label.
How to fix artwork that exceeds resolution limits
The four fixes, in order
- 1. Thicken problem strokes to at least 0.5 mm at label size. Convert text to outlines and thicken thin elements manually, or switch to a typeface with more uniform stroke width.
- 2. Remove unnecessary fine detail. Tagline URLs, hairline borders, intricate internal crest detail — remove anything that doesn't contribute meaningfully. A clean, bold brand name usually looks more premium anyway.
- 3. Increase label size if the design genuinely requires the fine detail. A 40 mm label can support what a 25 mm cannot.
- 4. Switch to a simpler font. Geometric sans-serifs (uniform stroke width, no serifs, open spacing) weave most cleanly. Script and decorative fonts are highest-risk for small labels.
Proof and sample process
- Free artwork review catches most issues within 48 hours — the digital proof shows how production will look, including any areas where detail won't resolve cleanly.
- Physical sample is the most reliable quality check for any design with significant fine detail. Request via the sample pack page.
- Flag specific concerns when submitting. Our team can assess complex crests, mixed-font designs, or logos with both fine detail and small text before the proof stage.
- Minimum label width: 0.8 cm (0.31 in) — Minimum label height: 0.8 cm (0.31 in)
- Minimum text height: 0.15 cm (0.06 in) — approximately 8 pt when document is set to physical dimensions
- Minimum stroke width (standard): 0.6–0.8 mm — below 0.5 mm is high risk
- Minimum stroke width (damask): 0.4–0.6 mm — below 0.35 mm is high risk