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Patches and Emblems

Detailed Application Instructions

Patches or emblems can be an excellent profit center for a small embroidery shop. Most companies that specialize in this product are quite large and require minimum quantities in the range of 100 pieces or more. However there are many customers looking for small quantities in the 5-24 piece range, who are not being serviced. You can take advantage of this, by offering small runs of custom emblems. The process is quite simple and can be used to embroider virtually any emblem of any shape or size. It is designed for using finished blank emblems, meaning emblems that have already been made and are awaiting embellishment. They are readily attainable from vendors who specialize in this product. The production process used by Companies that specialize in making patches from scratch involves special tools and processes that are not readily available to the average Embroidery Shop. The process begins with cutting out the fabric to be used to form the patch. (The most common fabric is twill.) This is done using specialty cutting machines such as die-cutters or lasers. Then a merrowed edge is applied (looks like a satin border, but is not) using a merrow machine. Depending upon the sophistication of the operation, embroidery is applied either before the cutting or after the patch is finished. However, in many cases the patches are sold “blank" and are referred to as “finished blanks." Unless you are going into patch production as a full-time endeavor, there is no need for you to invest in expensive and elaborate production systems. There are some simple methods that any Embroiderer can use. We will discuss the first technique here. The embroidery process involves hooping a piece of adhesive backing with the adhesive side up. The machine will be programmed to sew an outline that is the same size as the emblem and then stop. This outline serves as a template for applying the emblem. The emblem will be pressed firmly onto the adhesive backing using the template as a guide. Upon restarting, the machine, will embroider the actual design onto the emblem. This is a very simple method that ensures that the design is centered in the emblem each and every time, with no measuring required. This can be used for one patch or many patches. 



STEP 1: Create An Emblem Template File

Scan the emblem to be used. Digitize a running stitch around the outside edge of the scanned image. Be sure that the segment starts and stops at the TOP of the emblem. Save for use as an Emblem Template.









STEP 2: Create a Single Emblem File

Create a new file and bring in the Emblem Template File, created in Step 1. Merge/Paste/Create the desired logo and/or add lettering where you wish it to sew within the emblem. Ensure that the lettering or design has a color change at the beginning. Save this as a Single Emblem File.








STEP 3: Create a Multiple Emblem File (Optional)

For runs of more than one emblem, you can sew multiple emblems in one hoop. Choose a large hoop and determine how many emblems can be placed inside of it, without touching each other or the hoop. Create a new file and plot the location for each emblem. Use the copy function to place the Single Emblem in each of the plotted positions. Save this as s Multiple Emblem File.

TIP - Pulse users can display actual hoops on screen and use these images to help plot the multiple emblem locations.

TIP - If using a contract digitizer, have him set up some Outline files of basic emblem shapes for you. Then you can re-size them as necessary to create your own emblem templates. Thus, when you are doing just basic names, you can set them up yourself, using the MERGE function.




STEP 4: Sew The Outline Stitches

Choose a hoop large enough for the job and hoop a piece of adhesive backing with the "sticky" side up. (Peel N Sitck Backing is available at the Hirsch Online Storepart numbers 108062, 108063, 108064, 108065.)

As an alternative, you can use a heavy tearaway backing combined with a Spray Adhesive, both of which can be found at the Hirsch Online Store.

If you are running multiple emblems in the same hoop, program your machine to stop after it sews each outline running stitch.

Start the machine and it should sew the outline running stitch and then stop.





STEP 5: Apply The Emblem

Place the blank emblem down onto the adhesive backing using the outline running stitch as a template.














STEP 6: Apply The Final Embroidery

Restart the machine and it should sew the entire logo and then move back to the center of the design.













STEP 7: Running Multiple Patches

If sewing multiple emblems the machine should automatically move to the next emblem location, sew an outline running stitch and then stop. You will place the second emblem. Upon restarting the machine, it will complete the sewing process and move to the next location. This process continues until you have sewn all of the emblems that you setup for that hoop. When finished, simply unhoop and tear off the backing. You will notice that the outline running stitch does not attach itself to the emblem, it just goes with the excess backing.

NOTE: When sewing multiple emblems, do not attempt to remove any emblem from the adhesive backing until ALL emblems have been sewn.