Create Mixed Media Patches: Combine Embroidery With Sublimated Twill For An Elevated Look

Sublimated twill is vibrant and provides a wide variety of creative possibilities to your embroidery. In this guide we will walk through step-by-step as an overview for creating mixed media patches. Follow along with our detailed PDF guide that details the entire process.

Materials Needed:

Programs Required:

Step 1: Art Preparation

  1. Create Your Design: Use Adobe Illustrator or CorelDRAW to create your print art. Save the file as a version 8 .EPS.
  2. Add Embroidery Elements: Open that file in DesignShop and add embroidery elements like text or a faux marrow stitch around the edge to give it a true patch look.
  3. Set Up Design for Cutting and Sublimation:
    • In Illustrator, create your perf cut contour line for cutting on white twill. Make sure to delete vector elements that will be embroidered so they do not get printed.
    • Resize your artboard in Illustrator to match your heat press size to ensure proper sublimation registration.
    • Layout your design to fit the new artboard with some extra space around the edges. Add perf cut registration circles in the four corners for easy alignment of your cut twill with the printed artwork.
  4. Save Your File: Save the final design as a PDF.

Step 2: Cutting the Twill

  1. Load the PDF design into your cutter.
    • Use Cut Studio with an Illustrator plugin on the GS24 or VersaWorks on your Roland printer/cutter.
    • Load the PDF file and select the cut-only option.
  2. Cut the Twill: We recommend using white Poly Twill from Stahls.Use 60° blades for cutting the thicker material.

Step 3: Dye Sublimation

  1. Print the Art: Drag your art into Epson Edge (or your preferred printing software) and select the quantity to print.
  2. Align the Print: This is where your registration circles will come in handy. Remove the perf cut circles from the twill and align them with the black dots on your print.
  3. Sublimate the Twill:
    • Tape down the sides to prevent shifting.
    • Use the heat press (we recommend 400°F for 40 seconds at high pressure) then remove the sublimation paper immediately to prevent ghosting.

Step 4: Setting Up for Embroidery

  1. Load the Design: Import the design into Melco OS.
  2. Configure your Embroidery Machine:
    • Select your hoop. (We used the 7.25” x 7.25” Mighty Hoop.)
    • Set the color sequence.
    • Start with the placement stitch to show where to place the appliqué piece.
    • Add an appliqué pause to position the sublimated twill piece.
  3. Prepare for Embroidery:
    • Use Badge Master as the base material.
    • Hoop Badge Master drum-tight in the Mighty Hoop.

Step 5: Embroidering the Patch

  1. Placement Stitch: This will show where to place the appliqué piece within your hoop.
  2. Position the Patch: Once finished, place your sublimated patch in the placement stitch and start embroidering.
  3. Complete the Embroidery: Watch your design come to life as you stitch out the rest of your embroidered patch. You now have custom mixed media patches ready to decorate hats, bags, jackets, and more!


Creating mixed media patches is an easy way to elevate your projects. By combining embroidery with sublimation, you can achieve professional-quality mixed media designs that sell for a higher value than typical patches. Make sure to save this article for future reference.

Discover The EMT16X Advantage

In addition to being capable of networkable modularity, your multi-head setup retains all of these amazing capabilities of the Melco EMT16X

  • In commercial embroidery, speed is critical. With the ability to operate at up to 1500 stitches per minute, the EMT16X will help you keep your customers happy and speed up your ROI.
  • Melco embroidery machines are engineered for high-volume commercial embroidery applications and are designed to deliver consistent, high-quality embroidery work year in and year out.
  • Acti-Feed™ automatic thread tensioning makes the EMT16X easier to operate, reduces thread breaks, and ensures high-quality stitching.
  • The large 16.1″ x 15.5” sew field and compatibility with a wide array of hoops and hooping accessories means you won’t be limited on what kind of jobs you can take.
EMT16X multi-head embroidery machines