Why a JPG does not become an EXP just by changing the extension
JPG is the format of phone photos, of screenshots that arrive over WhatsApp and of almost everything downloaded from a website. It compresses the image by losing detail, so halos and dirty pixels appear around letters and edges and have to be cleaned up before digitizing.
An EXP file, on the other hand, is a list of instructions for the machine: move the needle, stitch, jump, trim and change thread. Going from one to the other is digitizing: redrawing the design as stitch objects and deciding the type, direction and order for each area.
How we turn the JPG to EXP, step by step
An image is a drawing; an embroidery file is a recipe for the machine. Getting from one to the other takes interpretation, which we do in five steps.
1. Clean up and simplify the image
We start from the JPG and remove noise, blurry edges and gradients. A thread is a single color, so the design is reduced to the shades that will actually be stitched (in a logo, usually between 1 and 8). Lines thinner than 1 or 1.5 mm are redrawn thicker, because thread cannot be thinner than that.
2. Decide final size, garment and fabric
A stitch has a fixed size; it does not scale like an image. That is why we ask how big the embroidery will be and what fabric it goes on: a stretch polo, a cap or a towel need different densities and underlays. With that information we digitize the design for that specific use.
3. Choose the stitch type for each area
We redraw the design as objects and assign each one a stitch, with its direction and density (the spacing between stitches is usually around 0.4 mm).
| Stitch | Used for | How it works |
|---|---|---|
| Running | Outlines, thin lines and small details | A simple, continuous stitch. It is the only one that can draw lines thinner than 1 mm. |
| Satin | Lettering and narrow shapes, 1 to 7 mm wide | Parallel stitches laid very close together for a smooth, glossy finish. If the area is wider, the thread snags and it switches to fill. |
| Fill (tatami) | Large areas of color | Rows of short, staggered stitches that cover wide surfaces with an even texture and no long loose threads. |
4. Technical adjustments that prevent puckering
- Underlay: base stitches underneath that hold the fabric and lift the satin so it does not sink in.
- Pull compensation: thread tightens the fabric as it is stitched, so we widen the shapes slightly to make the final result match the size of the original.
- Order and path: we stitch from background to detail and link nearby areas to reduce thread jumps and color changes.
- Tie-ins and trims: every section starts and ends secured, and trims are marked wherever there are long jumps.
5. Simulate, export and check
Before delivering we run the design through the stitch simulator: we look at the sequence, the stitch count and the thread changes, and fix whatever does not fit. Then we export it to EXP, check that it opens and that the simulation matches what we agreed, and send it to you with the color sheet.
The EXP format
EXP (Melco Expanded) is the format used by Bernina machines and commercial Melco machines. Like DST, it is a pure stitch format: very compatible but with no color information.
On home Bernina machines the color travels in a separate .INF file with the same name as the EXP. We deliver both together; if you copy only the EXP to the machine, the design embroiders fine but the colors on screen will not match.
| Brand | Use |
|---|---|
| Bernina | home and professional embroidery machines |
| Melco | commercial multi-needle machines |
| Others | many multi-needle machines accept it as an alternative format |
If you use Bernina software and want to be able to edit the design, also ask for the ART format in the notes.
How to prepare the JPG before sending it
- Send the largest version you have: from 1000 px on the short side we can work comfortably.
- Avoid screenshots of a photo or images forwarded several times through messaging apps: every forward compresses again and wipes out detail.
- If the logo has a colored background, mention it in the notes: JPG has no transparency, and we need to decide whether the background is stitched or not.
- If you have the same design as a PDF, SVG or AI file, send that instead of the JPG.
In this case: A JPG usually carries gradients and compression shadows. Since EXP does not store colors, we reduce the design to a few flat colors and send you the color sheet as a PDF for the operator.
How we convert it
- We review your fileWe check the JPG, clean up the edges and reduce the colors to real threads.
- We set size and fabricStitch density depends on the final size and the garment, so it is decided before digitizing and never rescaled afterwards.
- We digitize by handWe trace every area and choose the stitch type (running, satin or fill), direction, density, underlay and pull compensation.
- We simulate the embroideryWe check the sequence in the stitch simulator to remove unnecessary jumps and trims.
- We send it to youYou get the .EXP file with a preview and a sheet with colors, stitch count and dimensions.
What you receive
An .EXP file with its .INF color file for Bernina, a PDF color sheet and a preview.
If you also need the design in another format (for example for a workshop with an industrial machine), ask for it in the notes.
Frequently asked questions
Can a JPG be converted to EXP for free and automatically?
There are automatic converters, but a JPG contains no stitches: the software guesses direction, density and order, and the result tends to pucker the fabric, break thread or leave letters unreadable. They work as a draft for very simple designs. To embroider a real garment, the EXP must be digitized or reviewed by hand.
Which machines read the EXP format?
Bernina: home and professional embroidery machines. Melco: commercial multi-needle machines. Others: many multi-needle machines accept it as an alternative format. If you are not sure, put your machine model in the notes.
Is my JPG too small or blurry to embroider?
It is almost never an insurmountable problem. The JPG only serves as a template: the digitizer redraws every shape on top of it, so a slightly blurry image can be worked with. What cannot be invented is a detail you cannot see; if there is unreadable text, write it in the notes.
What is the .INF file that comes with the EXP for?
It stores the color list for home Bernina machines. Copy it into the same folder and with the same name as the EXP. Commercial Melco machines do not need it: the operator uses the color sheet.
How much does it cost to convert a JPG to EXP?
€5 (about $6) per design, and we send it to you in under 24 hours. If your design needed anything out of the ordinary, we will let you know before starting.