Comparing Custom Flag Processes: Choosing How Your Flag is Made
When designing a custom flag, one of the most important decisions you'll make is how it will be produced.
Each production method—embroidered, appliqué, screen printed, digitally printed, or vinyl—offers unique benefits depending on your design, quantity, and use-case.
This guide will help you choose the best flag process for your project.
Need a fast answer? Request a custom flag quote or call us today and we'll help you select the ideal method for your flag.
At-a-Glance Comparison of Custom Flag Processes
| Process | Best For | Durability | Visual Quality | Minimum Order | Cost |
|---|---|---|---|---|---|
| Embroidered | Indoor display, heirloom flags | Good | Excellent (Rich texture) | None | High |
| Appliqué / Sewn | Ceremonial, single flags | Good | Excellent | None | High |
| Screen Printed | Bulk orders, few colors | Great | Sharp (limited colors) | 6–12 | Lower (in bulk) |
| Digital Print | Full-color, small batches | Great | Excellent | None | Average |
| Vinyl Print | Banners, not meant to fly | Excellent | Excellent | None | Average |
Pros:
- Heirloom quality craftsmanship
- Rich look and feel up close
Cons:
- Heavy
- Can be a more expensive option
- Little to no quantity discount as each flag is hand made
- Difficult to make larger flags
Lead Time: 3-4 weeks
Minimum Quantity: None
Indoor/Outdoor Use: Indoor only
Clear, Crisp Lines: Good
Durability: Good
Flyability: Poor
Cost: High
Pros:
Cons:
Lead Time: 3-4 weeks
Minimum Quantity: None
Indoor/Outdoor Use: Great indoor, good outdoor
Clear, Crisp Lines: Good
Durability: Good
Flyability: Great
Cost: High
Pros:
Cons:
Lead Time: 2-3 weeks
Minimun Quantity: 6-12
Indoor/Outdoor Use: Great indoor or outdoor
Clear, Crisp Lines: Great
Durability: Great
Flyability: Great
Cost: Depends on quantity (lower pricing on larger quantities)
Pros:
Cons:
Lead Time: 2-3 weeks
Minimum Quantity: None
Indoor/Outdoor Use: Great indoor or outdoor
Clear, Crisp Lines: Great
Durability: Great
Flyability: Great
Cost: Average
Pros:
Cons:
Lead Time: 1-2 weeks
Minimum Quantity: None
Indoor/Outdoor Use: Great indoor or outdoor
Clear, Crisp Lines: Great
Durability: Great
Flyability: None
Cost: Average
Enhance Your Design with the Right Artwork
Each flag process has different artwork requirements. Make sure your files meet our artwork guidelines for the best results. Use our Nylon color chart to find the colors we carry in nylon fabric. And if you're unsure, our team can help you convert or prepare your files.
Can I Combine Processes?
Yes! Our team sometimes combines appliqué with digital print to create flags with intricate seals, multi-color logos, or photo elements. This hybrid approach gives you the rich texture of sewn elements with the versatility of full-color imagery.
The flag below is an example of a custom flag that demonstrates the use of both appliqué and digital print on both cotton and nylon materials.
PLEASE NOTE: If you think a combination of custom flag processes might be the best option for the flag you're looking to create, please call us for a recommendation on which processes to use.
We're Not Just a Leader in American Flags, We Excel in Creating Custom Flags!
Our team specializes in:
- Flags of any size that can be fully printed, and are economical in small to large quantities.
- One-of-a-kind banners and pennants are usually made with the appliqué process. This process is done on our own grounds. Our sewer Audrey does all of the sewing herself.
- Digital printing, screen printing, and screen dying on nylon, vinyl banners, and signs.
- Lettering or logos for application on window glass or plastics also available.
- are also available in heavy duty material or vinyl.
Interested in Creating a Custom Flag Using One of These Processes?
We'd love to help your custom flag vision come to life! Ready to create a flag with us? Give us a call at 1-888-697-3524 or and we can get the process started!
If you're planning to work with us, we recommend reviewing our artwork requirements so you know what to expect when it comes to submitting materials for your flag design.
Looking for some inspiration? Be sure to check out our wide variety of for ideas and to see some of the past custom flag work we've done.