Wildcard Week
Have you answered these questions?
Documented the workflow(s) and process(es) you used ✅
Explained how your process is not covered on other assignments
Described problems encountered (if any) and how you fixed them
Included original design files and source code
Included ‘hero shot’ of the result
🧵 Embroidery Machine Workflow
Design and produce something with a digital process (incorporating computer aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it. Possibilities include but are not limited to wildcard week examples.
During Wild Card Week, my instructor Silvana helped me with the coordination to carry out this activity at the Fab Lab ESAN. The goal was to explore a different type of technology that is not available at Fab Lab iFurniture.
Thanks to the support of Jorge, who are in charge of Fab Lab ESAN, a small master class was organized, led by Stephanie Urbano. Two classmates ( Jhasmin Ayala and Marita Chang ) who are also currently enrolled in the Fab Academy took part in the session as well.
1. Concept Development
The main goal was to determine what I wanted to embroider. To do this, I downloaded an image from website . The purpose was to embroider it onto cotton fabric and assess the limitations of the embroidery machine.
The fabric I used was Pima cotton, known for its softness and durability. The design I chose was a sakura flower.
2. Digital Design
The tool I will use to vectorize the image is Inkscape. However, in order to export the file from the software to the embroidery machine, it is necessary to install an additional plugin.
This plugin allows the vectorized design to be converted into a format compatible with the hardware, thus facilitating the embroidery process.
To do this, I go to the following link: inkstitch and click on the “Download” option. This plugin, called Ink/Stitch, integrates with Inkscape and allows you to prepare files compatible with the embroidery machine.
Once installed, Ink/Stitch provides specific tools to define stitch paths, adjust thread direction, simulate the result, and export the file in a format that the embroidery machine can read (such as .pes or .dst).
Next, I select the Windows download link, since that is the operating system my computer uses. This ensures that the installation of the Ink/Stitch plugin is compatible with my working environment.
Then, I click on the Windows 64-bit option, which matches the architecture of my operating system. This starts the download of the Ink/Stitch installer, compatible with Inkscape on my computer.
After clicking on Windows 64-bit, the installer download begins. Once it’s complete, I click "Run" to start the installation of the Ink/Stitch plugin on my computer.
Next, I select the destination folder where I will save the plugin during the installation. It’s important to choose an appropriate location to easily find the files later in case I need to make adjustments or reinstall.
Once I select the destination folder, I click "Finish", and the installation of the plugin officially begins. This completes the download and installation process of Ink/Stitch, making it ready to use within Inkscape.
I import the image in PNG. After importing the image, I convert it to a vector so the software can recognize the lines. I use the "Trace Bitmap" tool in Inkscape, which transforms the image into a vector graphic. format and open it in Inkscape. This will be the base file I’ll use to vectorize the design and prepare it for embroidery using Ink/Stitch.
From the top menu in Inkscape, I go to the "Extensions" tab and select the Ink/Stitch plugin. Then, I click on "Tools" and choose the "Fill - Tartan" option. This tool allows me to apply a tartan-style fill pattern to the selected area, simulating an interesting texture for the embroidery.
After selecting the "Tartan" option, a preview window opens showing how the embroidery will look. This window allows me to see how the fill pattern will affect the design and how it will appear once embroidered on the fabric.
To export the design, I go back to the "Extensions" menu, select Ink/Stitch, then choose "Visualize and Export", and finally click on "Stitch Plan Preview". This option generates a preview of the stitch plan for the embroidery, showing me how the design will be executed on the embroidery machine.
Next, a window titled "Stitch Plan Preview" opens, showing the stitch path of the design. In this window, I click "Apply" to confirm and apply the simulation. This helps verify the embroidery behavior before exporting it to the machine.
To export the final file, I select the destination folder and the export format. I choose Ink/Stitch: Brother Embroidery Format (.pes), which is compatible with the embroidery machine I will be using. Then I save the file in that location, making it ready to transfer and run on the machine.
Before finishing, I make sure to select the "Export Selection" option to ensure that only the selected object is exported. Then I click "Export" to save the file in .pes format. With this step, the design is fully ready to be used on the embroidery machine.
3. Prototyping & Testing
To begin this assignment, our instructor Stephanie Urbano gave us an initial explanation about the differences between types of embroidery. This introduction was essential for understanding the capabilities and limitations of the embroidery machine, as well as identifying which types of stitches are most suitable depending on the design and fabric.
Here, gathered with the instructor and my two colleagues during the master class, we were configuring our designs before moving on to fabrication. This moment was key for reviewing the embroidery settings and making sure everything was properly adjusted before sending the files to the machine.
The Brother Ellageo Plus embroidery machine supports a wide variety of stitching techniques, offering great versatility for different kinds of designs. Below are the main types of embroidery this machine can perform:
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Satin Stitch:
Ideal for creating smooth, solid-filled areas. It uses tight, overlapping stitches to cover a space evenly. This type of stitch is perfect for large lettering, logos, and intricate shapes, adding a professional and polished finish to any project.
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Zigzag Stitch:
A common decorative stitch that moves in a back-and-forth pattern. It's excellent for reinforcing edges, outlining shapes, or adding textured details. It also works well for filling small areas with color and design.
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Appliqué Embroidery:
This technique involves placing an additional piece of fabric onto the base fabric and stitching it in place using decorative edging stitches. It’s ideal for adding layered designs, textures, and reusing fabric scraps in creative ways.
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Chain Stitch Embroidery:
Forms a chain-like series of loops. It’s great for curved lines and organic shapes, such as leaves or hair in a design. It gives a softer, more hand-stitched appearance.
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Eyelet Embroidery:
This type of embroidery involves stitching around small holes or openings in the fabric. It’s often used to create decorative openings in clothing and adds a delicate, elegant touch.
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Running Stitch (Outline Stitch):
Mimics a hand-sewn line and is typically used for outlining shapes or adding fine details. It gives a clean and minimalist look, often used for sketch-style embroidery.
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Sequin Embroidery:
This technique attaches sequins or beads to the fabric using decorative stitches. It creates sparkling, eye-catching designs that are perfect for evening wear, costumes, or festive accessories.
Each technique creates different textures and visual effects, allowing for a wide range of creative possibilities in embroidery projects using the Brother Ellageo Plus.
The first prototype we created was a ladybug. This simple design allowed us to test the basic behavior of the embroidery machine, configure settings such as stitch type, density, and sewing order.
4. Machine Preparation
The Baby Lock Ellageo Plus is a versatile and user-friendly embroidery machine suitable for a wide range of creative projects. With its generous embroidery area, built-in designs, and intuitive controls, it’s an excellent tool for both personal and professional embroidery work.
User Manual: Baby Lock Ellageo Plus (BLL2)
1. Introduction
The Baby Lock Ellageo Plus (BLL2) is a high-end embroidery machine that combines advanced technology with user-friendly operation. It is ideal for custom embroidery projects and offers a wide range of features to meet the needs of both beginners and experienced users.
2. What’s Included
- Baby Lock Ellageo Plus (BLL2) embroidery machine
- Three embroidery hoops (including 6.25" x 10.25" size)
- Foot pedal
- Power cord
- User manual
- Quick reference guide
3. Technical Specifications
- Maximum embroidery area: 6.25" x 10.25" (160 x 260 mm)
- Embroidery speed: Up to 800 stitches per minute
- Connectivity: 2 USB ports (Type A and Type B)
- Built-in designs: 197 designs
- Built-in fonts: 11 monogramming fonts
- Supported file formats: .pes, .dst, .phc
- Display: High-resolution color touchscreen LCD
4. Initial Setup
a. Machine Setup
- Place the machine on a flat, stable surface.
- Connect the power cord to the machine and to a suitable power outlet.
- Turn on the machine using the switch located on the back.
b. Hoop Installation
- Select and insert the appropriate embroidery hoop into the embroidery unit.
- Ensure the hoop is securely attached and properly aligned.
c. Loading a Design
- Insert a USB drive with the desired embroidery file into the USB Type A port.
- On the touchscreen, select the "Design" icon, then choose "Load from USB".
- Browse the folders and select the file you want to embroider.
5. Basic Operation
a. Design Selection
- Tap the "Design" icon on the screen.
- Select from built-in designs or load from USB.
- Adjust size, position, and rotation as needed.
b. Stitch Settings
- Select the desired stitch type (e.g., satin, zigzag, etc.).
- Adjust stitch density and length based on fabric and design requirements.
c. Starting the Embroidery
- Hoop the fabric and secure it in the embroidery unit.
- Press the "Start" button on the touchscreen to begin stitching.
- The machine will automatically follow the programmed embroidery path.
6. Maintenance & Care
- Cleaning: Turn off the machine and clean the needle area and hoop regularly with a soft cloth.
- Oiling: Lubricate moving parts as recommended in the official manual.
- Needles: Replace the needle regularly and use the correct type for your fabric.
7. Common Troubleshooting
| Issue |
Suggested Solution |
| Machine not threading properly |
Check threading path and ensure the needle is installed correctly. |
| Design won’t load from USB |
Ensure the file format is supported (.pes, .dst, .phc) and the USB is properly inserted. |
| Embroidery stops mid-way |
Check for thread tangles and confirm there is enough thread loaded. |
Next, based on the size of the design, we choose the appropriate embroidery hoop. It's important to select a hoop that properly fits the design area to ensure precision and stability during the embroidery process.
In this case, we selected the smallest hoop, since the design was small and didn’t require a large embroidery area.
We placed the embroidery hoop onto the machine, and then selected the design file that we had previously saved on a USB drive. We connected the USB to the machine and followed these steps to load the file:
Steps to Select an Embroidery File from a USB on the Baby Lock Ellageo Plus:
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Turn on the machine.
Use the power switch located on the back of the Baby Lock Ellageo Plus.
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Insert the USB drive.
Plug the USB into the Type A port located on the right side of the machine.
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Tap the screen to enter the embroidery menu.
Select the "Embroidery" option on the touchscreen.
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Select the USB icon.
On the screen, tap the USB icon to access the files stored on the drive.
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Browse the files.
Look through the available files and select the embroidery design you want to use (it must be in .PES or another supported format).
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Load the design.
Once selected, press “Set” to load the design onto the embroidery screen.
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Adjust the position if needed.
You can move, rotate, or resize the design before starting the embroidery process.
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Press “Start”.
With everything in place and the thread loaded, press "Start" to begin the embroidery.
And this is the result of the prototype, using the tartan pattern.
5. Final Production
After learning the embroidery process and reading the manual, I choose the appropriate thread for the design I have.
For this project, I brought a light blue pima cotton polo, which is the material I will use. I chose a medium-sized hoop, and before placing it in the machine, we stretched the fabric as much as possible to ensure it is taut and even.
I select the file on the Ellageo Plus machine.
Did I have some problems during this project, but was I able to solve them?
The problems I encountered were two. The first, related to the type of embroidery, was that the fabric wasn’t optimal. It was too soft, which caused the thread to get tangled inside the machine. As a suggestion, since this type of embroidery is tartan, the fabric should be stiffer and less stretchy.
The second issue was mainly hardware-related. The pedal wasn’t making proper contact, which caused the machine to stop. This resulted in more time being needed, as the embroidery was estimated to take 47 minutes, but it took longer because the machine would stop every now and then, and I had to intervene to adjust the cable and ensure the pedal was properly connected.
6. Post-Processing
For the post-processing, what I did was simple: I removed the excess threads, since there were complications with the embroidery. I let it go past 85% since the machine kept stopping or the thread kept tangling, but the result was still nice. The total number of stitches was 1,329, which, according to the machine, should have taken 48 minutes, but in reality, it took longer because I had to adjust the power supply cable to prevent the machine from turning off every once in a while.
| Why Tartan? |
Chosen for its structured and symmetrical layout, which facilitates digital design and precise embroidery.
|
| Advantages |
• Easy to vectorize and program in Ink/Stitch.
• Repeatable with minimal error.
• Suitable for cotton fabrics like Pima.
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| Characteristics |
• Crisscrossed horizontal and vertical lines forming a checkered pattern.
• Scalable without distortion.
• Provides visual texture without overcomplicating the embroidery file.
|
Reflections
Adaptation to unexpected problems: During the embroidery process, I encountered several issues I hadn’t anticipated, such as the unsuitable fabric and the malfunctioning pedal. I learned that, while problems are inevitable, the key is to adapt and find solutions quickly. In this case, I was able to adjust the machine’s settings and make the necessary corrections to keep the work moving forward.
Patience and problem-solving: The embroidery process is not always straightforward, and patience plays a key role. Despite the issues with the pedal and the additional time I had to spend adjusting the machine, I learned that it’s essential not to lose composure and to solve each problem with precision. These situations taught me the importance of perseverance.
Time management and technology: Although the machine estimated an embroidery time of 48 minutes, the reality was different due to technical issues. This challenge taught me to be more mindful that machines don’t always perform as expected, and it’s important to have extra time available for unforeseen problems. I also realized the importance of checking and adjusting the technical aspects of the equipment beforehand to avoid delays.
Satisfaction with the final result: Despite the difficulties, the final result was satisfying. This project reminded me that, even though the path can be complicated, the effort and solutions applied pay off. Seeing the final outcome and knowing that I was able to overcome obstacles gave me a sense of accomplishment.
Access to files
sakura.pes
sakura.svg