Small detailed logo?

what type of fabric are you sewing on?

at the very least I hope you are using thinner 60wt threads and needles for this? Getting fine detail and smaller than usual lettering with standard 40 wt thread is probably asking too much. Often when we are requested to match something done offshore, we show that much of the detail work is in 60wt

3 very different fabrics to sew on and will yield 3 different results.

I assume you have told the digitizer the fabrics you are sewing on, correct? and your expectation?

density is one thing that can be changed. The suggestion about needles and thread above is another. the needle spacing in the design could be tightened up. there are several things that jump to mind but each will have an impact. could be good or bad. most of the time, you have to find a balance between the fabrics and advise the customer about how fabrics impact the sew out. In your case, you have 3 very different fabrics. If you get it to sew on the fleece like you want, its not going to sew on the polos the way you expect and vice versa.

I agree, 40 should work, but 60 will give you a much crisper look... just depends if these are regular product or if you want a higher, more polished look. "Just good enough" embroidery or "wow" embroidery. Try using a local digitizer who will provide you with the sewn sample, then you are assured of the quality up front. That could save you alot of headache with any order!