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I'm actually very very interested in this opinionated approach to patch design -- can you tell me more? Or refer me to some useful design guides? I can just google something random too, but it sounds like you might know / have some good resources already

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The term you'll want to search for is "digitizing". It's roughly the embroidery equivalent of CAM design in CNC manufacturing.

Depending on how much time you have, this video[0] is a decent in-depth overview[1] of the various ins and outs of embroidery patch digitizing. I'd give it a watch while you're on a walk or something.

[0] https://www.youtube.com/live/jATHlfz8mtM?si=Lvw-ZTq8tmLg9ij-

[1] Heh, "in-depth overview" sounds like a total oxymoron. Hopefully you get what I meant!

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