It is not inevitable, though lightweight jersey is one of the more demanding fabrics to embroider. Puckering usually comes from a combination of things. The fabric is stretched or poorly supported while it is stitched. The design packs too many stitches into a small area. The thread tension is too high. Or the fabric shrinks differently from the embroidery when washed. Each can be adjusted at the sampling stage.

Support the fabric properly

Knit fabric needs a stabiliser, or backing, chosen for knits. Ask the factory which backing it uses and whether it is cut-away or tear-away; embroiderers often prefer cut-away types on stretchy knits because they stay in place to support the stitches. Also ask how the garment is hooped. Stretching jersey in the hoop and then releasing it after stitching is a common cause of rippling.

Adjust the design for the fabric

Stitch count and density matter on light fabric. A logo digitised for a heavy hoodie may be too dense for a lightweight tee. Ask the factory's digitiser whether the file has been adapted for knit jersey, for example with lighter fill density or adjusted underlay. A small change to the design file is often the cheapest fix.

Check after washing

You mention it gets worse after washing. That points to differing shrinkage between the fabric and the embroidery, or to a backing that does not hold up. Wash embroidered samples under a named procedure such as ISO 6330 and the conditions on your care label, then compare with unwashed samples. Make sure the care label, built on ISO 3758 symbols or text, matches the conditions the embroidered garment actually tolerates.

Approve a washed sample

For the reorder, approve an embroidered sample that has been washed, not only a new one. Record the backing type, design file version and machine settings with the approval, so bulk production follows the same set-up.

Placement matters too. A logo sitting over a seam or very close to the neckline is harder to keep flat. Confirm the placement measurement from the shoulder point and centre front on the approved sample.

If the fabric itself shrinks a lot, address that too. A stable fabric makes every decoration easier.