How is an embroidered patch created?
It all starts with a need, and an idea. Original artwork is submitted by the buyer and it is modified to meet customer and production requirements – does the patch need to be simple or complex, large or small, standard square/diamond, triangular, rectangular or oval? What’s the background color and how many colors of thread will be used? With advanced computer technology, complex, intricate image designs are easily transferred via embroidery to fabric.
Once the design is finalized, it is digitally scanned and the image is feed into computerized stitching machines. These industrial sewing machines have multiple heads and create embroidered art with chain, satin and hemming stitches. Polyester blend threads are more commonly used instead of standard cotton sewing thread. This poly thread retains color better than organic materials, providing vibrant, brighter colors that resist fading and last longer.
Hundreds of these identical patch images are machine stitched on the sheets of backing material and edge stitching is applied. Known as a marrowed border, this serge stitching provides a nice clean, finished edge that won’t fray or unravel. Each patch is then die-cut out of the fabric sheet and a thin plastic coating is applied to the back of the patches. The addition of this plastic sheet seals the fabric, preventing any loose threads from unraveling and adds stiffness, preventing the patch from wrinkling or puckering.
Complicated, uneven edging that can’t easily be marrowed is instead finished with an embroidered edge and the patches are then robotically cut with a laser.
This method is used for such odd-shaped patches as the silhouette of many of the U.S. states and other irregular images. More information on embroidered patches from the Chicago Embroidery Company is available at www.c-emblem.com or ask a question at firstname.lastname@example.org