Patches are awesome. This guide will help you learn how to make patches on the MakerFX Barudan Elite embroidery machine, but this process is the same even for other types of embroidery machines.

NOTE: This tutorial assumes you already know how to load thread, load a file, set the origin, etc. You can get started by embroidering the design on a piece of stabilizer first to ensure that it works well before going through the full patch process.

This guide was written by Ian Cole, feel free to ask questions or ask for a 1:1 to get started!

Getting Started

Watch this video for an overview of the process - Embroidery Hub Ep. 28: DIY Patches | Bulk Patch Embroidery Tutorial
Check out the Learning Resources at the bottom of this guide to see some step-by-step overviews on different websites. There are a LOT of variations on how to do this process, so it can get a bit overwhelming. I'll show you here what worked well for me on our Barudan machine.

Materials Used for Making Patches

Quilting cotton with patterned designs - its a bit thin, but looks great with designs, especially with bright colors
Twill - I've experimented with Twill iron-on patches and now looking for a source of twill by the yard
Spray Adhesive - Dritz Quilting Adhesive Spray - DO NOT USE STANDARD ADHESIVES, they can gum up the needles
Standard Stabilizer (I've been using the roll)
Water Soluble Stabilizer (Need to note the Pellon # that I've been using)
Border Color bobbin (optional) - you can use a border color bobbin when doing the border. This isn't required, but adds a pro level of finish.

Prepping the Art

There are a few different ways to approach patch making. You can take an existing embroidery design and a separate applique / patch border and use them together, OR you can design a custom patch file. You need a "dieline" which is a single perimeter stitch for placement, a zig-zag tack down stitch (optional, but recommended), the patch edge border, and the main design for the patch.

For this tutorial, I used two designs from Urban Threads.

Designs: UTZ1143 - Patch Border - Circle and UT2006 - Anatomical Skull

I purchased the designs, downloaded the .dst files, downloaded the thread list pdf (example), then selected matching threads using the Madeira online rayon thread color guide (since Urban Threads specifies their colors using Madeira thread.

Making the Patch

Steps:

Art Prep
- Need the embroidery Design
- Need an outer circle stitch - I used embird to add a "basting stitch" in the editor.
Gather Materials

Cut a piece of material and standard stabilizer / backing - use the spray adhesive to fuse them together

Hoop the fabric + standard backing

Embroider the dieline on the fabric and backing

Cut the fabric + backing very close to the dieline

Hoop the water soluble stabilizer

Embroider the dieline on the water soluble stabilizer

Apply spray adhesive to back of the fabric + backing

Place the fabric + backing onto the water soluble stabilizer using the dieline as a guide

If you have a zigzag stitch line for attaching the patch (like in the Urban Threads patch borders) use it to attach the patch - otherwise, start embroidering the border. If your patch needs the border done last, strongly recommend using a zigzag attaching stitch.

Embroider the border, then the center art - Note that PROs use a border color bobbin when doing the border. This isn't required, but adds a pro level of finish.