Built from the edge. Ready to finish clean.

Building the embroidery file for a patch: the outline, the base, the interior design and the border, planned for the way the patch will be finished. We supply the stitch file; the patch itself is sewn and finished in production.

No. We prepare the embroidery file a patch is sewn from. Sewing, cutting, merrowing and backing are done by your own shop or by a patch manufacturer, so send us their machine format and finishing method.

A patch has no garment to support it once it is cut out, and its edge is part of the design. The file plans the base, border, cut line and density so the finished piece stays flat, stiff and clean at the edge, instead of just placing a logo inside a shape.

Yes. Custom and irregular outlines usually suit a sewn satin edge that is then cut with a hot knife or laser. Send the shape you want, or an existing cut file, and we build the outline and border to match.

A satin border is stitched as part of the design file, and the patch is then cut close to it, commonly with a hot knife (on polyester twill) or a laser. A merrowed edge is an overlock stitch added on a separate merrow machine after the patch has been embroidered and cut, so the embroidery file does not sew it; we leave a clean outline and placement for it. Merrow machines handle circles, ovals and gentle curves well but not sharp corners or tight inward turns, so custom outlines usually get a satin border or a heat- or laser-cut edge instead.

It depends on the patch. In many twill patches the placement line, tack-down and border can sew before the design details. On dense designs, or patches built on film or water-soluble stabilizer, the satin border is often sewn last so the heavy stitching does not pull the patch out of shape or weaken the stabilizer before the edge is finished. We plan the order for your design and production method.

Yes, that is what a twill-base patch is. The fabric forms the background and only the design is stitched. It is lighter and quicker to sew, and works well when the background is a single solid color.

Yes. Full-stitch patches cover the whole surface in thread, which looks richer and feels thicker but takes more stitches. Background fills are layered and angled so the patch stays flat.

Yes. We can include a run line where the cut should fall, or match the outline to a cut file you already use. Tell us your cutting method when you request a quote.

Vector artwork (AI, EPS or PDF) is preferred; a clear PNG or JPG can be reviewed. Include the finished size, the shape and the edge method if you know it. For the outline itself, vector art can help when you only have a low-resolution image.

Patch shops usually run DST or EXP on multi-head machines, and we also supply PES and other formats. Tell us your machine and cutting method.

Usually. Puckering, gaps and distorted outlines come from fabric pulling under the stitches, which underlay, backing and pull compensation are there to control; bulky corners come from satin stitches crowding where the border turns, and a border without enough underlay can look thin or uneven. Send the file with a photo of the sewn patch and we tell you whether we would correct or rebuild it before any work starts.

The finishing backings do not: iron-on, hook-and-loop and sew-on backings are applied after the patch is stitched, so they are not part of the file. The material the patch is sewn on does matter. On film or water-soluble stabilizer, dense stitching can perforate the stabilizer, so the border may be sewn after the design and the construction is planned to hold together once the stabilizer is gone. Tell us how the patches will be made.

Yes, for free-standing styles. The file needs heavier underlay and a solid border so the patch holds together once the stabilizer is washed away. Let us know so we build it that way.

Each patch design is quoted before any work starts. The quote depends on the size and detail of the design, whether the background is twill or fully stitched, the border type, and how many sizes or versions you need. We supply the stitch file only; making, cutting, merrowing and backing the patches is done by your shop or patch maker. See pricing and policies.