An embroidered patch file is a normal stitch file with one extra job: it sews its own edge. You stitch the design and a satin border onto a firm fabric such as twill, then cut the patch out just outside the border. In SatinSmith, the border is added automatically when the artwork's background is a filled shape that spans the whole design, such as a filled circle or shield behind the logo. Every download includes all 8 formats, so the same patch works on home and commercial machines.
Artwork that works as a patch
A patch needs a clear outer shape you can cut around. Good patch artwork has:
- A filled outer shape. A circle, shield, rectangle or rounded badge, filled with color, behind the whole design. That filled background is what gets the satin border. An outline on its own, or floating text with nothing behind it, won't get one, so put a filled shape behind it first.
- A few solid colors. Flat fills sew cleanly; gradients and shadows don't.
- Text that's big enough. Keep letters at least about 6 mm (1/4 in) tall at the finished size. On a 100 mm patch, that rules out a long slogan in small type.
- Simple edges. Smooth curves and wide corners are easier to border and to cut out than sharp spikes.
No artwork yet? Choose AI design in the Artwork panel and describe it, for example "a round badge with a mountain and sun for a hiking club". If your logo is blurry or low resolution, clean it up first.
| Patch size | Width | Typical use |
|---|---|---|
| Small | 50 to 75 mm (2 to 3 in) | Caps and sleeves |
| Medium | 75 to 90 mm (3 to 3.5 in) | Left chest, bags, uniforms |
| Patch preset | 100 mm (3.9 in) | Standard round or shield badges; fits a 5×7 in hoop, not a 4×4 in |
| Large | 200 to 250 mm (8 to 10 in) | Jacket backs |
Step by step: make the patch file and sew it
Upload the artwork
Open the studio, choose Image in the Artwork panel and upload a PNG, JPG or WebP of the badge, or use AI design to draw one.
Choose the Patch size
In the Size panel pick Patch (100 mm, 3.9 in) as a starting point, or choose Custom and type an exact width. The size doesn't switch the border on or off; the filled background shape does.
Set the fabric to Woven
Patches are usually sewn on twill, which is a stable woven, so choose Woven in the Fabric panel.
Check the border in the preview
Play the stitch-out and look for a smooth, even satin border around the whole outside. No border usually means there's no filled shape behind the whole design. If the badge color runs right to the edges of the image, Auto remove may treat it as background, so open Advanced and set Background to Keep all. Patches are often filled edge to edge, so check the density map and the Checks tab too. Our guide to reading the preview and checks explains each warning.
Download the file
Unlock the design and pick your machine to get the right format, such as PES for Brother or DST for commercial machines.
Hoop twill with a firm stabilizer
Hoop a piece of twill bigger than the patch, with a firm stabilizer behind it. A heavy tear-away or a firm cut-away is a common choice. Twill is stable, so hoop it flat and tight.
Sew, unhoop and trim the back
Sew the patch, take it out of the hoop and remove the excess stabilizer from the back.
Cut it out
Cut around the outside of the satin border with small, sharp scissors, as close as you can without nicking the stitches. On polyester twill, many embroiderers use a hot knife to seal the edge as they cut. Then sew the patch on, add an iron-on backing or stitch hook-and-loop to the back.
Satin border vs merrowed edge
Many commercial patches have a merrowed edge: a thick, rounded overlock stitch that wraps over the cut edge. It's sewn on a separate merrow machine after the patch is cut out, so an embroidery machine can't make it. A satin border is sewn by the embroidery machine itself, as part of the design, so it works on any embroidery machine and can follow any shape.
| Edge type | Satin border | Merrowed edge |
|---|---|---|
| Made on | Any embroidery machine, as part of the file | A separate merrow (overlock) machine |
| Shapes | Any shape, including points and inside corners | Best on simple shapes such as circles, ovals and rectangles |
| Cut edge | Cut just outside the border after sewing | Wrapped in thread, so the cut edge is covered |
| Look | Flat, smooth border | Raised, rounded edge |
If you don't have a merrow machine, the satin border is the practical choice, and it looks clean when it's cut neatly. For the difference between satin and fill stitches in general, see satin vs fill stitch.
Questions
What fabric is best for embroidered patches?
Twill is the most common patch fabric. It's stable, holds dense stitching without puckering and cuts cleanly. Polyester twill can also be sealed with a hot knife as you cut.
Can I make a merrowed patch on my embroidery machine?
No. A merrowed edge is sewn on a merrow machine after the patch is cut out. Your embroidery machine can sew a satin border instead, and that works on any shape.
What size should an embroidered patch be?
Many patches are 3 to 4 in (75 to 100 mm) wide, which suits a chest, bag or uniform. SatinSmith's Patch preset is 100 mm (3.9 in). Cap and sleeve patches are usually smaller, and jacket-back patches much larger.
How do I attach an embroidered patch?
Sew it on around the border, add an iron-on adhesive backing, or stitch hook-and-loop to the back. Sewing it on is usually the most durable option for items that are washed often.