Appliqué and a Bevelled 3D Effect

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.