Full embroidery and full printing means outlining / base color fully embroidered as the foundation + gradual color changes / complex color digital printing for coloring. This solves the problems that full embroidery cannot achieve gradual color changes and that too many color gradations lead to high costs. It is the mainstream and high-end technique in embroidery stamps.
Drawing organization
Customer AI/PNG/JPG patterns, graphic design layering: outer contour, large area base color (for full embroidery), gradient / fine and fragmented colors (for printing), size marking, Pantone color, edge processing, back adhesive type.
Embroidery layout
The layouter uses embroidery software to make patterns: outer frame with border lines, large area areas are fully embroidered as the base (full embroidery), hollow areas reserved for printing positions; polyester embroidery thread with matching color numbers is selected.
Color separation layout for printing
The printing end makes a positioning dot file, matching the embroidery outline positioning coordinates to prevent printing and embroidery misalignment.
Sample making and confirmation
Small batch trial production of samples, checking color, positioning, thickness, feel, customer signature to seal the sample, locking the main production process.
Computer machine full embroidery base (full embroidery process)
The base fabric and paper are combined and fixed on the embroidery machine frame, stretched and flattened to prevent wrinkling and shifting.
Embroidery machine reading the pattern operation:
① First, embroider the outer contour border (lock edge shaping)
② Fill the internal area with full stitches, covering the base color, leaving white space for the pattern positioning frame
Continuous and batch embroidery of the entire piece, one pattern can be embroidered with multiple patterns at once
After embroidery, trim the floating lines and thread ends, and remove the waste paper from the back side
Laser cutting of individual patches
After the entire piece is embroidered, it is sent to the laser cutting machine. The outer contour is precisely cut to separate it into individual embroidered patches;
Advantages: Smooth cuts without frayed edges, precise alignment, avoiding deformation caused by manual cutting.
Digital direct printing (full printing process, integration of printing and embroidery)
Fixed positioning
The cut-out embroidery patterns are adhered to the sticky positioning platform, arranged neatly, and then scanned and positioned by machine vision, matching the embroidery contour coordinates.
Digital direct coloring
The digital printing machine sprays environmentally friendly coating ink, printing gradient, photo-level patterns, complex multi-color details in the blank areas of the embroidery;
It can print multiple pieces simultaneously on the same sheet, with high efficiency and natural color transition, and the gradient colors that cannot be achieved by embroidery can be completed through printing.
Drying and fixation
After printing, it is sent to the tunnel drying oven / heat press machine for high-temperature drying, the ink penetrates and sets, resistant to water washing without bleeding or ink loss.
Post-processing (backing adhesive + trimming + arrangement)
Apply backing adhesive (optional)
Cover the back with heat-sensitive adhesive film and press with a heat press at 120-140℃ to create a heat-pressed backing adhesive label; it can also be used as Velcro, pins, or double-sided self-adhesive backing.
Fine edge processing
Optional: heat-cutting for edge sealing, edge reinforcement, and trimming the rough edges to prevent thread breakage during long-term washing.
Full inspection and sorting
Check one by one: misalignment of printing and embroidery, missed printing, skipped lines, color difference, dirt spots, and poor cutting. Discard defective products and rework them.
Final packaging and shipment
Count the quantities, sort by category and pack separately, attach serial number labels, pack and ship in boxes.
Advantages: It has both the three-dimensional texture and the crisp feel of embroidery, as well as the rich and varied colors of the printed pattern. The design is of high quality and high standard.
Disadvantages: The production process is more complex than simply full embroidery or plain printing. The production cost is higher and the production cycle is longer.
Dongguan Evergreenbadges Co., Ltd.
Our product range including:embroidered patches, woven patches, chenille patches, printed patches, leather patches, PVC patches, silicone embossed patches, epaulettes and brassards.
Addromess: 2nd Building, No. 5, Guxia Industrial 2nd Rd., Shipai Town, Dongguan City, Guangdong Province
Phone: +86-769-87036875 / +86-18898701468
Email: sales@egbadges.c
Post time: Jun-18-2026
