Embedded Files
Real stitched approvals.
Technical clarity.
Production-ready confidence.
We deliver real stitched samples — not simulations.
Your file is tested on a calibrated Tajima, then delivered with a production-ready Approval Card.
Why APPROVALSTITCH ?
Why APPROVALSTITCH ?
Real Stitch Lab Accuracy
Real Stitch Lab Accuracy
Real stitches. Real production behavior.
We don’t simulate. We test your file on a Tajima single-head…
Technical Clarity
Technical Clarity
Every sample includes detailed technical notes: underlay, density, pull compensation, stitch direction and fabric-specific settings.
Production-Ready Confidence
Production-Ready Confidence
Calibrated approval cards with real stitched samples — measured, aligned, and color-listed for production accuracy.
Your Sample. Tested. Verified. Ready.
Because your production deserves a tested file, not a guess.
Because your production deserves a tested file, not a guess.
Real Work. Real Quality. Real Approval.
Your designs, stitched with laboratory-level precision — not simulations, not guesses.
Your designs, stitched with laboratory-level precision — not simulations, not guesses.
REAL TEST STITCHES
REAL TEST STITCHES
Real Samples. Zero Guesswork.
Real Samples. Zero Guesswork.
We stitch every design on a calibrated Tajima single-head machine — the same machines used by industry-leading apparel manufacturers.
BEFORE / AFTER — FIX & REBUILD
BEFORE / AFTER — FIX & REBUILD
This is where 35+ years of digitizing and sampling experience makes the difference.
This is where 35+ years of digitizing and sampling experience makes the difference.
Your files aren’t just “fixed” — they’re rebuilt for real production.
PREMIUM APPROVAL CARD
PREMIUM APPROVAL CARD
Measured. Verified. Production-Ready.
Every Approval Card we deliver includes a fully documented sample — measurements, colors, stitch count, and a real stitched photo.
Brands use this card to approve production without further revisions. Measured. Verified. Production-Ready.
Every Approval Card we deliver includes a fully documented sample — measurements, colors, stitch count, and a real stitched photo.
How It Works
How It Works
A seamless flow from upload to a production-ready approval card.
A seamless flow from upload to a production-ready approval card.
UPLOAD & DETAILS
UPLOAD & DETAILS
Upload Your Artwork & Job Specs
Upload Your Artwork & Job Specs
We start with your artwork and the details that matter — size, fabric, color, and special requirements
DIGITIZING & TECH SETUP
DIGITIZING & TECH SETUP
Precision Digitizing, Calibrated for Real Fabric Behavior
Precision Digitizing, Calibrated for Real Fabric Behavior
Your file isn’t “just digitized. It’s engineered for the specific fabric and the way real stitches behave on a Tajima machine.
REAL APPROVAL STITCH
REAL APPROVAL STITCH
We Stitch It on a Tajima Single-Head Machine
We Stitch It on a Tajima Single-Head Machine
This is the core of ApprovalStitch — your design is stitched in our lab under true production conditions.
APPROVAL CARD DELIVERY
APPROVAL CARD DELIVERY
You Receive a Full Approval Package
You Receive a Full Approval Package
Your Approval Card includes everything needed for production — verified, measured, and ready for client approval.
Rebuild your DST with real stitched accuracy.
Rebuild your DST with real stitched accuracy.
Production-ready corrections based on a calibrated 6×6 inch approval sample.
Production-ready corrections based on a calibrated 6×6 inch approval sample.
• Real stitched verification
• Real stitched verification
• Clean pathing & sequencing
• Clean pathing & sequencing
• Balanced density for your fabric
• Balanced density for your fabric
• Bulletproof underlay + compensation
• Bulletproof underlay + compensation
• 300 DPI approval scan included
• 300 DPI approval scan included
Why Fix Your DST?
Why Fix Your DST?
Most DST files were created with outdated settings, wrong densities, or unstable pathing.
Most DST files were created with outdated settings, wrong densities, or unstable pathing.
Fixing your DST improves:
Fixing your DST improves:
• Stitch quality & clarity
• Stitch quality & clarity
• Edge cleanliness
• Edge cleanliness
• Fabric behavior
• Fabric behavior
• Thread-break reduction
• Thread-break reduction
• Production speed & consistency
• Production speed & consistency
A cleaner, stabilized DST saves time and improves every stitch-out.
A cleaner, stabilized DST saves time and improves every stitch-out.
Common Problems We Fix
Common Problems We Fix
Typical issues we correct:
Typical issues we correct:
• Wrong densities
• Wrong densities
• Bad satin direction
• Bad satin direction
• Poor underlay
• Poor underlay
• Sharp angle changes
• Sharp angle changes
• Excessive trims & jumps
• Excessive trims & jumps
• Flattened 3D puff areas
• Flattened 3D puff areas
• Crooked results from bad push/pull
• Crooked results from bad push/pull
• Unstable pathing and long travel stitches
• Unstable pathing and long travel stitches
• Inconsistent sequencing causing distortion
• Inconsistent sequencing causing distortion
Before & After
Before & After
Your file is rebuilt from scratch — not “fixed.”
Your file is rebuilt from scratch — not “fixed.”
What improves:
What improves:
• Cleaner edges & smoother outlines
• Cleaner edges & smoother outlines
• Correct densities for your fabric
• Correct densities for your fabric
• Balanced pathing & sequencing
• Balanced pathing & sequencing
• Strong underlay + proper compensation
• Strong underlay + proper compensation
• Better stitch flow & fewer defects
• Better stitch flow & fewer defects
• 300 DPI approval scan included
• 300 DPI approval scan included
Rebuilt DST = production-ready accuracy.
Rebuilt DST = production-ready accuracy.
Bird Nesting (Thread Birdnesting)
Bird Nesting (Thread Birdnesting)
Large thread buildup under the hoop caused by weak tie-ins, low upper tension, poor pathing, or excessive density.
Fix: optimized tie-in/tie-off, corrected density, clean stitch flow.
Thread Breaks
Thread Breaks
Frequent thread breaks caused by high density, poor column structure, long travel stitches, or wrong pathing.
Fix: density balancing, satin/fill correction, optimized pathing.
Misalignment (Registration Off)
Misalignment (Registration Off)
Letters, outlines, or color blocks don’t line up.
Cause: wrong stitch order, insufficient compensation, unstable pathing.
Fix: proper push-pull, optimized sequence, balanced structure.
Density Issues (Too High / Too Low)
Density Issues (Too High / Too Low)
Too high density → puckering & thread breaks.
Too low density → gaps & visible fabric.
Fix: fabric-matched density + proper fill angle.
Fabric Flagging
Fabric Flagging
Fabric lifts upward with the needle, creating distortion.
Fix: stronger underlay, proper satin width, correct needle/thread setup.
Stitch Gaps (Holes in Fills)
Stitch Gaps (Holes in Fills)
Visible gaps in fill areas due to wrong fill angle, low density, weak underlay, or poor compensation.
Fix: adjusted fill direction, balanced density, corrected underlay.
Registration Errors (Multi-Color Misalignment)
Registration Errors (Multi-Color Misalignment)
Colors shift relative to each other.
Fix: corrected sequence order, compensation, and consolidation of color blocks.
Underlay Problems
Underlay Problems
Weak or incorrect underlay causes unstable shapes and poor coverage.
Fix: correct underlay type (edge-walk, zigzag, fill) matched to fabric & design.
Pathing & Excessive Trims
Pathing & Excessive Trims
Unnecessary jumps and trims increase machine stops and slow production.
Fix: redesigned pathing + optimized color flow.
Satin Problems
Satin Problems
Over-wide satin columns, wrong angles, or insufficient edge support lead to distortion.
Fix: recalibrated satin width, angle, compensation, and edge underlay.
Service Options
Service Options
✔ Re-Digitize + Real Stitch
✔ Re-Digitize + Real Stitch
Best for:
• Low-quality DST files
• Wrong densities or poor underlay
• Broken paths and unstable shapes
• Old files needing full rebuild
Outcome:
• File rebuilt from the ground up
• New real stitched sample + 300 DPI scan
✔ Puff / Lurex Sample
✔ Puff / Lurex Sample
Best for:
• Collapsed 3D Puff areas
• Metallic thread issues
• Puff logos stitched with wrong density/underlay
Outcome:
• Puff/metallic setup corrected
• Real stitched proof + 300 DPI scan
✔ Burmilana Sample
✔ Burmilana Sample
Best for:
• Wool-texture recovery
• Incorrect heavy-thread settings
• Patch logos with frayed or flattened texture
Outcome:
• Wool-optimized stitched sample
• Correct density + proper underlay
What You Receive
What You Receive
Fully rebuilt DST + EMB
Real stitched sample
300 DPI scan
Approval Card (size based on your design)
Stitch count + notes
Thread color list
File ready for mass production
✔ "Your file is engineered specifically for your fabric type, thread selection, and production method."
✔ "Your file is engineered specifically for your fabric type, thread selection, and production method."
✔ Re-Digitize + Real Stitch
✔ Re-Digitize + Real Stitch
Best for:
• Low-quality DST files
• Wrong densities or poor underlay
• Broken paths and unstable shapes
• Old files needing full rebuild
Outcome:
• File rebuilt from the ground up
• New real stitched sample + 300 DPI scan
✔ Puff / Lurex Sample
✔ Puff / Lurex Sample
Best for:
• Collapsed 3D Puff areas
• Metallic thread issues
• Puff logos stitched with wrong density/underlay
Outcome:
• Puff/metallic setup corrected
• Real stitched proof + 300 DPI scan
✔ Burmilana Sample
✔ Burmilana Sample
Best for:
• Wool-texture recovery
• Incorrect heavy-thread settings
• Patch logos with frayed or flattened texture
Outcome:
• Wool-optimized stitched sample
• Correct density + proper underlay
9 PREMIUM SAMPLES
9 PREMIUM SAMPLES
SpencerStuart – Corporate Text
SpencerStuart – Corporate Text
Size: 2.60 × 0.75 in
Stitch Count: 3,213
Thread Colors: 1 (White)
Fabric: Piqué polo
Production Time: 5 min
Thread Used: 40 ft
Dungeon Wrestling Club
Dungeon Wrestling Club
Size: 3.70 × 2.56 in
Stitch Count: 19,787
Thread Colors: 3 (Grey, White, Green)
Fabric: Piqué polo
Production Time: 25 min
Thread Used: 325 ft
Gold Canyon
Gold Canyon
Size: 2.30 × 2.90 in
Stitch Count: 10,089
Thread Colors: 3 (Blue, Navy, White)
Fabric: Performance poly
Production Time: 15 min
Thread Used: 140 ft
Lion Emblem (Troutman/Lion Shield) – School Crest
Lion Emblem (Troutman/Lion Shield) – School Crest
Size: 1.97 × 2.23 in
Stitch Count: 10,723
Thread Colors: 2 (Navy, Yellow)
Fabric: Performance poly
Production Time: 14 min
Thread Used: 185 ft
Sparty Mascot – Sports Icon
Sparty Mascot – Sports Icon
Size: 1.60 × 2.51 in
Stitch Count: 9,515
Thread Colors: 4 (White, Brown, Grey, Green)
Fabric: Performance poly
Production Time: 18 min
Thread Used: 172 ft
NCAA National Champions – Patch Style-Multi Layer Fill
NCAA National Champions – Patch Style-Multi Layer Fill
Size: 4.20 × 4.00 in
Stitch Count: 32,559
Thread Colors: 4 (Navy, White, Orange, Grey)
Fabric: Jersey
Production Time: 45 min
Thread Used: 620 ft
Rutgers Health – Corporate Logo
Rutgers Health – Corporate Logo
Size: 4.20 × 1.20 in
Stitch Count: 7,565
Thread Colors: 2 (Red, Black)
Fabric: Patagonia knit
Production Time: 11 min
Thread Used: 120 ft
MLB | TBS – Media Patch
MLB | TBS – Media Patch
Size: 2.59 × 0.87 in
Stitch Count: 6,843
Thread Colors: 4 (White, Red, Navy, Black)
Fabric: Piqué polo
Production Time: 10 min
Thread Used: 115 ft
Available Thread Colors & Fabric Colors
Available Thread Colors & Fabric Colors
Place your order below and specify your preferred fabric and thread colors.
Madeira is our primary thread brand.
RA and Isacord numbers are provided for color-matching reference.
Federal Reserve Bank – Fine-Detail Crest
Federal Reserve Bank – Fine-Detail Crest
Size: 3.80 × 3.00 in
Stitch Count: 23,829
Thread Colors: 2 (White, Black)
Fabric: Piqué polo
Production Time: 30 min
Thread Used: 355 ft
Start Your Order
Start Your Order
Send your embroidery file and receive a real stitched approval sample within 12–24 hours.
Upload Your Embroidery File
We accept all standard embroidery formats. Your sample will be stitched on real fabric, scanned, photographed, and delivered with production-ready details:
Upload Your Embroidery File
We accept all standard embroidery formats. Your sample will be stitched on real fabric, scanned, photographed, and delivered with production-ready details:
• High-resolution scan
• Real stitched photos
• Thread colors used
• Verified, production-ready stitch file
• Digitizing available when artwork is provided.
Accepted File Types
Accepted File Types
DST, EMB, PXF, EXP, DSB, PES, JEF, VP3
Artwork formats (PNG, JPG, PDF, AI, EPS) are also accepted when digitizing is needed.
How It Works
How It Works
Upload your DST/EMB file (or artwork if digitizing is needed)
We prepare fabric, thread colors, hooping, and tension
Your approval sample is stitched on real fabric
We scan and photograph it in high resolution
You receive your real sample + production-ready stitch file
Turnaround Time
Turnaround Time
Standard: 12–24 hours
Complex samples: 24–48 hours
Trusted Worldwide
Trusted Worldwide
Used by apparel decorators, promotional product groups, agencies, and independent brands across the US and Europe.
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