Vintage workwear fan Will Petersen of Monster Press created this embroidered design as a more efficient alternative to a traditional merrow patch
The concept…
When Monster Press started exploring the possibility of offering embroidered patches on caps, it hit a snag. “That process can be a bit of a faff to manage in-house, and we knew that there would be high minimums required,” explains operations director, Will Petersen.
“We like the look of vintage workwear style, and patch caps are something we thought looked cool, so we created this faux merrow patch-style embroidery as a more efficient alternative. We produced this design as a sample to showcase our embroidery capabilities and let customers see for themselves how good the faux patch can look.
The edge of the design was digitised to mimic an embroidered patch sewn onto the cap
The walkthrough…
The edge of the design was digitised to mimic an embroidered patch sewn onto the cap.
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The design was embroidered onto the AS Colour Class cap in walnut.
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The faux patch was stitched on a Tajima TMEZ 6-head embroidery machine. The TMEZ model includes i-TM (Intelligent Thread Management), which automatically adjusts upper thread tension.
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The Tajima TMEZ 6-head machine also features a DCP (Digitally Controlled Presser Foot), which adapts to fabric thickness to reduce flutter and stitch defects.
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The total stitch count of the design was 15,000 at 800spm.
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Four layers of black fill were added for extra density.
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The design was stitched out using 75/11 Schmetz Sharp Needles and Madeira Polyneon 40 thread.
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There were some issues with the fill stitch density on the unstructured cap, which caused slight misalignment. This problem was solved by using two layers of Madeira Cap backing, one horizontally and one vertically up the centre of the hat, along with tight clips to minimise movement.
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