Creating a custom patch involves more work than one might think. There are multiple steps to the process...
Step 1 - The mock-up: This step is essentially the "blueprint" of the patch. The goal is to create a design that is simple and straight forward yet, still pleasing to the eye. When thinking of embroidery, it is important to understand that EVERY single detail in the design will translate when digitizing.. size, stray marks, random lines, etc. With that said, make sure to be fully intentional when coming up with your design. Once the customer creates a rough draft, Jets will finalize the design, turning it into what we call "patch art". Once the final mock-up is approved, then we move on to the next step.
Step 2 - Digitizing: This step involves creating a computerized map of the design so it is compatible with the embroidery machine. It's more or less converting a JPEG file into whats called a PES file. This conversion is what the machine needs to read the "language" of the design. Digitizing is mandatory and without it the machine will not know what to sew-out.
Step 3 - Sew-out: Once the digitizing is complete, it is now time to hoop the fabric and sew-out the design. There are many variables when it comes to this step. Depending on the stitch count, size, complexity and amount of colors, it's possible that the design may take anywhere from 5-20 minutes to sew-out. There is even a possibility it may take longer than 20 minutes depending if there are any thread breaks, needle breaks, bunching of thread or any other machine malfunctions.
Step 4 - Trimming: Now that the patch is sewn onto the fabric, each one gets cut, trimmed, glued and burned out individually. Once the patch is cut away from the fabric, there are multiple thin lines of thread connected to one another that must be trimmed. As soon as the patch is clean and legible, it is now time to glue and burn the edges to ensure they won't fray.
Step 5 - Heat-press: The final step to creating a patch requires the application of iron-on glue. This is done individually with a heat-press. The glue is essential because it stiffens up the fabric and helps the patch remain crisp and flat. It's also convenient because now the patch can be applied to almost any fabric based surface with the help of an iron. Once the glue cools, the patches are complete.
This process is a perfected science that Jets has mastered. You will be 100% happy with the final product, GUARANTEED !! Please don't hesitate to ask any questions about this process, Jets would be happy to give you any information you're wondering about.
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