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Rayon is a softer thread, it gives a nicer look to the embroidery, it's available in more shades. Poly stands up to heavier/regular washing, less likely to break.

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Better if you stick to one or the other across your machine as they will require different tensions.

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My first machine came with rayon so I used that for a couple of years. Then I switched to polyester because I became concerned about rayon thread bleeding when washed and I liked the cheaper cost and longer life poly provided. I’m so glad I made the change. In addition to being cheaper and less subject to bleeding, poly ran much better and faster and having fewer thread shades made it easier to pick thread. Today 99% of my thread is poly. I do run rayon occasionally when I need to PMS match a color or need 60 wt thread for fine detail (more 60wt colors are available than in poly). 95% of my work consists of business logos so I’m not recreating fine color shading. If I embroidered realistic designs like animals or plant life using rayon might give my designs more realistic shading because more colors are available and it has more sheen.

I would guess poly is more popular today just because of the lower cost and ability to run at a faster speed but think that’s somewhat dependent on what type of thread ships with new machines.
 

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Discussion Starter · #7 ·
My first machine came with rayon so I used that for a couple of years. Then I switched to polyester because I became concerned about rayon thread bleeding when washed and I liked the cheaper cost and longer life poly provided. I’m so glad I made the change. In addition to being cheaper and less subject to bleeding, poly ran much better and faster and having fewer thread shades made it easier to pick thread. Today 99% of my thread is poly. I do run rayon occasionally when I need to PMS match a color or need 60 wt thread for fine detail (more 60wt colors are available than in poly). 95% of my work consists of business logos so I’m not recreating fine color shading. If I embroidered realistic designs like animals or plant life using rayon might give my designs more realistic shading because more colors are available and it has more sheen.

I would guess poly is more popular today just because of the lower cost and ability to run at a faster speed but think that’s somewhat dependent on what type of thread ships with new machines.
Thank you for your detailed response It helped me a lot. My new machine came loaded with rayon and I was trying to see if I should use the Poly instead.
 

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Poly all the time. I use a variety of brands for colour match purposes but always Poly where i can. I recently used Rayon on a specific job to match their existing logo on their garments and it was a real pain, it is really weak by comparison and broke all the time!
 

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I prefer poly, mostly because of the look. Rayon is VERY shiny, where poly can be shiny or dull. Both come in a huge variety of colors, I don't think you are limited by either type. I prefer Madeira less breakage than most others.

I've never ran into bleeding or wearing out with either type, I just prefer the look of poly.

It really is just what look you or your customer prefer.
 

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There are some companies that basically run rayon but use poly for reds (least stable color - most likely to run), white and black. Bobbin tensions should be adjusted different depending on if you're using rayon or poly but people run both types for the same design without issues. The important thing is to adjust the upper thread tensions.

Apparel that is industrially laundered (kitchen staff clothing) should be embroidered with poly. When you have a red logo embroidered on a white garment I would use polyester thread because you never know how your customer will launder the item.
 
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