An EXP file is Melco's expanded embroidery format. Melco commercial machines use it, and Bernina embroidery machines read it too. Like DST, it stores stitches, jumps and color changes but not the thread colors themselves. You make one by digitizing a logo or lettering into stitches and saving the result as EXP.
| EXP | What to know |
|---|---|
| Origin | Melco's expanded format |
| Read by | Melco commercial machines and Bernina embroidery machines |
| Thread colors | Not stored. Color-change stops only |
| File type | Expanded: finished stitches, no editable shapes |
| Companion files | Bernina designs often come with a matching .inf file that holds the colors |
What "expanded" means
Embroidery files come in two broad kinds. A working file stores shapes, such as a satin column or a fill area, and software turns those shapes into stitches. An expanded file stores the stitches that came out the other end, every one written out in order. EXP is the expanded kind. That makes it dependable to sew and easy for a machine to read, but it isn't built for editing: enlarge an EXP a lot and the stitches spread apart; shrink it and they pile up.
In practice, an EXP holds:
- Each stitch as a short move from the one before, so long travels are broken into several jumps.
- Color-change stops that tell the machine to pause or switch needles.
- Jumps between separate parts of the design.
- No thread colors. Nothing in the file says which shade sews each part.
EXP on Bernina and on Melco
On a Bernina, you load an EXP from a USB stick or send it from Bernina's own software on models that support it. The machine sews one color block at a time and stops for you to change thread. Because the EXP carries no colors, the screen may show stand-in colors that don't match your design.
That's where the .inf file comes in. Designs saved by Bernina software, or sold for Bernina machines, often arrive with a small .inf file of the same name next to the EXP. It typically holds the thread colors the EXP can't, so keep the two files together in the same folder. A SatinSmith download gives you the EXP itself, so take the colors from the Production sheet instead.
On a Melco commercial machine, the operator assigns a needle to each color stop, just as a Tajima operator does with a DST. If your shop runs Melco alongside other brands, keep both an EXP and a DST of each design. A SatinSmith download includes both, along with PES and JEF for any home machines. For how the color-free and color-carrying formats compare, read DST vs PES.
How to make an EXP file in SatinSmith
- Open the studio. Choose Image for a logo file, Lettering for names and text, or AI design to describe a design in words and have it drawn for you.
- Set the width under Size and the material under Fabric. For linen, silk or quilting cotton, pick Light: it uses a lighter fill so the fabric doesn't pucker.
- Play the preview, then read Checks for stitch length and density, and Details for the stitch count and machine time.
- Unlock the download and pick your machine, or take the .zip of all 8 formats and use the
.expfile. - Print the Production sheet. Since the EXP has no colors, this sheet is your thread list.
Every panel is covered in how to turn a logo into an embroidery file, and thread colors and the production sheet explains how to match each color to a real spool. Stitch one on the actual fabric before a run, especially on light fabrics, which show puckering first.
Common EXP problems
- Wrong colors on screen. That's expected with EXP. Thread the machine from your list, not from the screen.
- Colors are right on one machine and wrong on another. One copy probably has its .inf file alongside and the other doesn't. Copy both files together.
- The design is rejected as too big. Bernina hoops and sewing fields vary by model, so check the manual. Reduce the width in the Size panel and download again; re-downloads of an unlocked design are free.
- The file doesn't show up. Make sure the name ends in
.expand the file sits where your machine looks for designs, usually the top level of the USB stick.
Questions
Is EXP the same as DST?
No, but they're close cousins. Both are expanded formats that store stitches and color stops without thread colors. EXP comes from Melco and DST from Tajima, and they encode the stitches differently, so you can't just rename one to the other. Most embroidery programs convert between them.
Do Bernina machines use EXP?
Yes, Bernina embroidery machines read EXP files, and it's the format to choose for a Bernina from a SatinSmith download. Your manual lists any other formats your model supports.
What is the .inf file next to an EXP?
It's a small companion file that Bernina software often saves with an EXP. It typically holds the thread colors, which the EXP itself can't store. Keep it in the same folder with the same name, or work from a thread list if you don't have one.