Wilcom Collectible Patches

Follow our monthly blog to unlock expert tips and take your embroidery to the next level. Collect a patch each month and build your creative skills — one stitch at a time!

Skull Design

File Type: 2025 and e4. EMB file formats

Compatible With: 
All EmbroideryStudio products from e4 and above, and Truesizer.

Get Your Free Patch Today

Simply fill out the form below, to access the download.

Advanced Embroidery Techniques

Step-by Step Guide to 
Appliqué and a Bevelled 3D Effect  

Part 1: Lettering Setup (Appliqué Letters)

1. Create Lettering

• Font: Pastille  |  Height: 50mm  |  Spacing: 13mm
  

2. Apply Outlines and Offsets

• Offset: 1mm Run Stitch  |  Corners: Rounded 
• Remove check box – 'Create offsets for holes' and  'Keep original objects'

3. Frame out Position

• Create a crosshair guide for the frame out positioning.

4. Convert to Appliqué

• Select all > Right-click > Convert to Appliqué.

5. Reshape Letters

• In Reshape mode, adjust appliqué objects so letters don’t overlap.
  
  Note: Any adjustments to an applique object will auto-adjust the Guide, Tack, and Cover stitch at the same time, so you don’t have to adjust the individual layers.

6. Add Decorative Motif Outline

• Outlines & Offsets: 2mm Motif Run (Green)
• Use an existing Motif or create your own.
• Check – 'Keep original objects' and 'Create offsets for holes'

Part 2: Preparing Appliqué Pieces

7. Export Shapes for Cutter
   • Go to File > Export Multi Decoration > Export Current Design > Appliqué Shapes.
   • Export to the format required by your cutter.

8. Optimize in CorelDRAW

• Open vector file in CorelDRAW.
• Adjust graphics, flip shapes where useful (e.g. flip the “L”) to minimise fabric waste.

9. Combine Components

• Click back into EmbroideryStudio workspace. To optimize the stitch sequencing for applique..
• Select the appliqué objects.
• Combine Appliqué Components to streamline sequencing and reduce color changes.

Part 3: Digitize the Skull
 

10. Digitize Skull Base
    • Digitize all non 3D embroidery first
    • Digitize the skull, create a Custom Program Split for the skull. (Program Split Fill (custom split created from skull image).
    • For the eyes, apply Tatami fill with Spiral effect.
    • Add Column A satin objects for the outline of the skull.

11. Foam Preparation
    • Digitize and use 2 layers of foam for the skull outline. To avoid flattening the 3D puff, raise the presser foot to 5mm (if the machine allows).

⚠️ Tip: Change to a fresh needle and reduce machine speed to reduce breaks.

Stitch over the foam a second time with an extra wide satin cover stitch

12. Secure Foam

• Use standard satin to secure the foam, density: 0.40mm.
• Extra wide Satin cover stitch = 3x the width of the foam.
• Always cap the ends for 3D foam stability.

13. Remove Foam

• After stitching, peel away the excess foam for the reveal.

• Use Column A satin stitch.
• Density: 0.16mm. (tight density)
• Stitch length: 10.49mm (this is an extremely long satin stitch, but it’s required to create the bevelled 3D effect)
• Speed: Slow down machine to ~200 rpm for clean coverage over high foam.

Appliqué and a Bevelled 3D Effect Result: Bold lettering with vinyl appliqué and a striking bevelled 3D skull design that adds depth and texture.

Embroidery Among the Stars 

When Wilcom shared the Wilcom in Space story of Indian astronaut Shukra Sharma wearing Wilcom-digitized patches on the Axiom-4 mission, it was already a proud milestone. But now we’ve learned something even more extraordinary. On the very same spacecraft...

With decades of expertise, Tamás not only digitized the embroidery but also stitched the patches that traveled with Mr. Kapu into orbit, and once again sees Wilcom in space.

Spotlight on Hungary

Hungary, though a small country, has proudly established its own space program, HUNOR – Hungarian to Orbit. In June 2025, astronaut Tibor Kapu, a mechanical engineer, traveled to the International Space Station as part of Axiom-4, conducting dozens of scientific experiments.

Axiom-4 Hungarian astronaut

Celebrating the Achievement

Designing embroidery for space travel is no ordinary task. Every stitch must endure preparation, travel, and the honor of representing a nation. For this reason, Tamás and the Palesz Kft. team were entrusted with Hungary’s patches, delivering embroidery of extraordinary quality for a mission unlike any other.

We warmly congratulate Tamás and the Palesz Kft. team for this outstanding achievement.

Reaching for the Stars 

And Hungary wasn’t alone. Through our vibrant Wilcom community, we’ve since discovered that the Polish astronaut also wore Wilcom-crafted embroidery during Axiom-4, digitized by Andrzej Śniadek from EDS Studio, for the IGNIS Space Agency.

Congratulations to Andrzej Śniadek 

Axiom-4 Polish astronaut

Three Nations United by One Embroidery Technology

✅ Hungary – digitized by Tamás Pálkerti
✅ India – digitized by Chandra Shekhar
✅ Poland – digitized by Andrzej Śniadek

To the best of our knowledge, three out of four astronauts aboard Axiom-4 proudly wore Wilcom embroidery in orbit. 

National Pride

Each patch was more than embroidery — it was a symbol of national pride. Whether representing Hungary’s HUNOR program, India’s growing space ambitions, or Poland’s space partnerships, these designs reflected decades of expertise and the global power of Wilcom software.

👉 Join 385,000+ professionals worldwide who trust Wilcom every day.

A Drew Nelson Original

One of the most exciting things about embroidery is seeing how creative minds push tools in new directions. Our Reef PhotoStitch feature is designed to convert incredibly complex images to a single-color run stitch that concentrates on the darker areas of an image.

When placed in the hands of a passionate digitizer, it produces truly stunning results.

Over the past few days, Drew has shared some incredible new creations on social media, each one highlighting his growing mastery of this unique stitch type. 

By layering, he creates texture, depth, and movement, showing how a single-color feature can be used to transform embroidery into stunning multi-colour designs.

Layer Colors of Reef PhotoStitch

Get Inspired 

We love seeing what our community creates, and Drew’s work is a reminder of the endless possibilities when skill meets innovation. Be sure to follow his journey for more inspiration, and maybe experiment with Reef PhotoStitch in your own designs.

Drew Nelson’s 
Lighthouse Design

Free Download

Animate with Embroidery: 
Beating Heart With Photo Flash

Bringing Embroidery to Life

Imagine embroidery that doesn’t just sit still but appears to move! With Wilcom’s innovative tools and techniques, you can create mesmerizing embroidery effects. We are starting with a pulsing, beating heart!

This technique combines Photo Flash embroidery with the magic of barrier-grid animation, allowing stitched designs to come alive with motion. Let’s dive in!

How Does It Work?
The Magic of Barrier-Grid Animation

Barrier-grid animation, also known as picket-fence animation, is a fascinating visual effect that creates movement through a striped transparent overlay placed over an interlaced image. As the overlay moves, different parts of the design are revealed, producing the illusion of animation.

This technique has been explored in various forms over the years. Notably, artist and inventor Rufus Butler Seder developed Scanimation, a patented application of barrier-grid animation used in his interactive books and artwork. While our approach is inspired by the same fundamental principles of optical illusion, it is a unique adaptation for embroidery, made possible through Wilcom’s Photo Flash feature.

Watch as the heart appears to beat before your eyes!

What is Photo Flash?

Photo Flash is a powerful tool in Wilcom EmbroideryStudio that automatically converts varying color densities in an image into different stitch thicknesses. Darker tones produce denser embroidery, while lighter shades create thinner stitched lines. 

Tip: Before designing, test your color density by creating a grayscale—this helps you see how Photo Flash will interpret the stitch density.

Step-by-Step: Creating the Beating Heart

Design Your Heart – Use at least four shades of color within a single design to create distinct sections that will make up the movement.

Apply Photo Flash – Import your graphic and apply Photo Flash to automatically convert your design to stitches. Use the settings listed above to achieve the stitch density distribution for the best visual effect.

Embroider the Heart – Stitch out the design. We’ve selected red thread for our heart.

Prepare the Overlay – Print stripes onto a transparent film. Ensure the stripe width matches the spacing in your design.

Bring It to Life! – Place the stripes on top of your embroidery and gently move it side to side or keep it still and shift your perspective to see the animation effect.

Photo Flash is included in EmbroideryStudio Designing.

It is also available in the Decorating level subscription plan as an exclusive feature.

What Can You Create With This Technique? 

Unique embroidered artwork, animated embroidered greeting cards, interactive apparel & accessories, soft furnishings, sensory designs and more.

Bring embroidery to life in a way that’s both unexpected and mesmerizing. Explore new creative possibilities and try this unique effect for yourself!

If you plan to use this technique for commercial purposes, please be aware that Scanimation is a patented method, and a license may be required. We strongly recommend researching the relevant intellectual property rights before proceeding. Wilcom is not selling or using this technique for commercial purposes; our focus is on showcasing the creative potential of embroidery.

Get Your Free 'Beating Heart' Embroidery

As a special gift from us, download the beating heart embroidery design, graphics and grid and start experimenting with animated embroidery today!

Embroidery is nothing like print — it’s a unique medium with its own rules. That sounds obvious, but it’s a crucial distinction to understand, especially for anyone new to digitizing and learning the embroidery basics of push and pull compensation.

A beginner might digitize a design on screen exactly as it appears in the printed form, and it looks perfect, only to find that it appears distorted or misaligned once stitched out. Why? Because unlike print, embroidery interacts with a physical medium—fabric—and this medium fights back.

This is one of the key concepts that distinguishes embroidery from graphic design: push and pull compensation, often simply referred to as "Pull Comp."

Why You Need to Understand Pull Compensation

When a needle punctures fabric and thread is stitched, tension is created. This tension distorts the original design, affecting its shape and proportions.

In short:

Pull makes stitches narrower, pulling them inward along their width.
Push makes stitches longer, pushing them outward along their length.

What is Push and Pull Compensation?

In simple terms, pull compensation adds width to your stitches during digitizing to balance out how the fabric reacts during embroidery.

You are intentionally overcompensating—adding just enough extra width so that, once the fabric pulls and compresses during stitching, the final result appears correct.

It’s an invisible correction, but it makes all the difference between a professional-quality result and a disappointing one.

When Pull Compensation Matters Most

FONTS: 

Keep Lettering on a Perfect Baseline: Lettering is particularly sensitive to pull. Left uncorrected, certain letters may appear smaller or drift off the baseline. Pull compensation keeps them sharp, legible, and aligned.

CIRCLES: 

Digitize Perfect Circles: Without push and pull compensation, circles can flatten into ovals. Adding the right amount helps maintain symmetry and ensures a visually balanced result—even on tricky fabrics.

OUTLINES: 

Outlines and Registration: Whether it’s a run stitch outline or a satin border, outlines rely on precise placement. The natural push and pull of embroidery can throw this off. Try slightly stepping the outline inward.

Factors That Affect Pull Comp 

Several things influence how much pull compensation you’ll need:

🔹 Stitch Type

• Satin Stitch has the most visible pull effect. It pulls inward (along the sides) and pushes out (at the ends), especially in long or narrow columns.
• Tatami Stitch shows less pull comp overall but is still affected, especially over large fill areas.

🔹 Fabric Type

Knits stretch more than woven fabrics, so pull compensation must be increased to account for extra movement. Every fabric reacts differently—testing is essential.

🔹 Object Size

The bigger the object, the more obvious the pull comp. A small pull compensation setting that’s unnoticeable in a 10mm letter becomes very obvious in a 100mm satin border.

Over time, experience helps you use every tool at your disposal to manage pull compensation effectively. Including the best pull comp settings for you.

Underlay Plays a Role, Too

These underlay stitches support your pull compensation, helping your embroidery hold its shape.

Stabilizers Matter, Too

Stabilizers add essential support from underneath the fabric. By keeping the fabric taut and minimizing stretch or movement during stitching, stabilizers work hand-in-hand with your underlay and pull compensation settings to prevent distortion and ensure crisp, accurate embroidery.

When to Adjust Push and Pull Compensation

There’s no universal formula for push and pull compensation. The correct adjustment comes with experience and depends on several factors, including fabric type, stitch style, object size, and machine tension..... That’s why testing is critical. 

Wilcom’s EmbroideryStudio makes this process simpler:

• Use object-based editing to control pull compensation per element
• Access and adjust pull comp values in the Object Properties Docker (Default settings are available to get you started)
• And remember: test, test, test—it’s the only way to truly see the effects.

Pull Compensation options are available in every level of EmbroideryStudio software and can be found in the Object Properties Docker.

From Studio to Space Station: The Story of India’s Space Patch

Group Captain Shubhanshu Shukla became the first Indian to reach and return from the International Space Station aboard Axiom Mission 4 (Ax-4), marking a historic milestone for India — the country’s first visit to the ISS in 41 years.

This patch, brought to life using Wilcom’s EmbroideryStudio software by Mr. Chandra Shekhar of Pulse Embroidery, a design and digitizing studio based in Bangalore, India. It had to be lightweight (no more than 14 grams), durable enough for space, and symbolically rich in meaning.

“The real game changer in this project was Wilcom EmbroideryStudio. It made this intricate design easy to complete — just an hour and 15 minutes to digitize,” says Chandra Shekhar V.

This isn’t Wilcom’s first journey into orbit!

The Power of Wilcom in Precision Digitizing

With a complete understanding of Wilcom EmbroideryStudio, Mr. Chandra Shekhar carefully chose and fine-tuned stitch types and settings to maintain visual impact while minimizing weight.

Here’s how Wilcom’s tools made it possible:

• Tatami with Offset Pattern – Used for the background fill, this mirrored the texture of the original artwork while reducing stitch density.
• Contour Stitches on Orbital Lines – Created a clean, linear effect representing Earth’s orbital paths.
• Florentine Effect – Added movement and depth to curved stitches, echoing the shape of a space station.
• Motif Fill – Formed the Earth with minimal stitches, maximizing visual clarity and impact.
• Smart Stitch Combinations for the Details – From satin to tatami to run stitches, each was carefully selected to illustrate the moon phases, scientific symbols, and the sun.
  
  

A Global Triumph — with an Indian Signature

We are reminded of how embroidery — powered by advanced digitizing software — continues to break new ground, quite literally reaching for the stars - and getting there

Run Stitch Outlines

Before we dive into some handy tips on EmbroideryStudio’s run stitch outlines, we couldn’t resist mixing a bit of stitch humor with practical advice!

We may not all be lacing up our sneakers, but if you’re threading up your embroidery machine, you’re technically still doing some running… right? 😉

Scroll to the bottom of this blog to download your free embroidery design: "If I Use Running Stitch, Can I Count It as Exercise?" 🧵😄

Digitizing Run Stitch Outlines

Wilcom's EmbroideryStudio 2025 offers a wide range of stitch types — from creative textures to specialty outlines. Here, we’re focusing on one of the most versatile and essential: Run Stitch. 

Perfect for outlines and fine detailing, it’s a staple in every digitizer’s toolbox.

Outline Stitch Types in EmbroideryStudio

Run, Sculpture, Triple, Backstitch, and Stemstitch, available in Decorating and Designing.
(Motif and String Stitch are included in the Designing level only.)

Outlining Tip for Production Flexibility

When digitizing logos, always assign the text and outline to separate needle allocations.

Why? 

This ensures the outline of the design is NOT linked to the text, providing flexibility to embroider the logo on garments of any color— essential for production runs across multiple garment colors.

The logo uses three thread colors, and the production order includes
6 WHITE Polo Shirts and 6 NAVY Polo Shirts

Black text is unreadable on navy shirts

 

White outline differs from the original design

Below, the logo has been digitized with FOUR needle assignments. The Run Stitch outlines were assigned to a separate needle, allowing color adjustments without interrupting production flow.

Thread Color Linkages Matter! 

Same logo design, multiple color combinations — all thanks to smart design planning and EmbroideryStudio's all-in-one EMB file!

Your Free Download
"If I Use Running Stitch, Can I Count It as Exercise?"

File Type: 2025 and e4. EMB file format

Compatible With: 
All e4 and above EmbroideryStudio products and Truesizer

Stitch Fest FREE Downloads
Start Your Collection!

As part of Stitch Fest 2025, we’re giving you exclusive access to a growing collection of Stitch Fest free downloads - embroidery designs, and Wilcom's Collectible Patches — all created to inspire, educate, and spark your creativity.

Whether you’re a seasoned digitizer or just starting out, these designs offer a great opportunity to study professional techniques and sharpen your skills.

Stitch Fest 2025 also brings exciting promotions on EmbroideryStudio 2025 products. 

Best of all? More free designs are on the way!

 In case you missed the 'The Needle Bar LIVE Special Episode'
Click the link below to watch it: Watch 

✨ More Coming Soon!

This is just the beginning. We’ll be releasing more free designs and collectible patches.