In the past I have used a Brother SE6000 sewing machine to embroider onto items such as pillows and bags but I had never made a patch. This machine is not quite set up to make patches. The main obstacle is that the border of a patch encapsulates the edge of the fabric so there are no loose edges. This can be achieved by having the fabric suspended in wash-away embroidery stabilizer. There are a few issues when doing this on a sewing machine. The main issue is that it is incredibly difficult to exactly place a piece of fabric in the machine where the machine will trace the fabrics border. The other option is to have the first pass of the machine outline the shape of the patch onto a full sheet of fabric and then to cut away the excess. However, this is tricky in its own right. I also found that high quality wash-away stabilizer is expensive. The cheap stuff is flimsy and tears easily, even when using multiple sheets. This page outlines how I was able to make patches that mostly look high quality but don't require wash-away stabilizer.
This is a design that my brother asked me to turn into a patch. I used Adobe Illustrator to outline the image and to create a border for the patch. Then, I opened an SVG version of this image in Inkscape and used the Inkstitch extension to turn the image into a PES file.Â
Once I had the PES file, I used a usb to move the file to the embroidery machine. I then started the machine and switched out the colors accordingly.
This is another set of patches that I made upon request from my cousin. To make this design in Illustrator, I typed the words and then outlined the stroke and used the "offset" tool to make the border.
Once I have a design embroidered onto a piece of fabric, I use one-sided iron-on adhesive on the back. Then I cut really close to the border of the design with a sharp pair of scissors. I color in any sort of gaps with a sharpie. I seal the entire border off with some fabric glue.