Learn Optimize Wilcom stitch flow

Optimizing stitch flow in Wilcom Embroidery Studio is crucial for achieving a high-quality embroidery design. A well-optimized stitch flow ensures that the design stitches efficiently, reducing production time, minimizing thread breaks, and improving the final appearance. Here’s a detailed guide on how to optimize stitch flow in Wilcom:

Optimize Wilcom stitch flow

1. Plan the Stitch Sequence

• Logical Stitching Order: Plan the order in which elements of the design will be stitched. The general rule is to start stitching from the background to the foreground, stitching larger elements first and moving to smaller details.
• Minimize Color Changes: Group objects of the same color together to minimize color changes. This reduces production time and ensures a smoother stitching process.
• Sequence Adjustments: Use the Resequence tool in Wilcom to adjust the stitching sequence. This tool allows you to drag and reorder elements to achieve the desired stitch flow.

2. Use Underlay Stitches for Stability

• Add Underlay Stitches: Underlay stitches provide a foundation for top stitches and help maintain the fabric’s stability during embroidery. This is especially important for designs on stretchy or unstable fabrics.
• Types of Underlay:
• Edge Run: Provides a strong edge for satin stitches and helps prevent fraying.
• Zigzag: Offers additional support for satin stitches, especially on thicker fabrics.
• Tatami: Suitable for fill areas, providing a flat base for the top stitches.
• Optimized Settings: In Object Properties, adjust the underlay settings based on the fabric type and design complexity. Use only as much underlay as needed to avoid excessive stitch density.

3. Optimize Stitch Density

• Appropriate Density: Set the stitch density to match the fabric and design size. High stitch density can cause puckering and thread breaks, while low density can result in a lack of coverage.
• Density Settings:
• For Satin Stitches, a density of 0.35 to 0.45mm is typical.
• For Tatami Fills, a density of 0.4 to 0.6mm works well for most fabrics.
• Auto Density: Use the Auto Density feature to let Wilcom automatically adjust the density based on the object size.

4. Use Appropriate Stitch Types

• Satin Stitches: Ideal for narrow columns and borders. Avoid using satin stitches for wide areas (wider than 8mm) as they may become too loose or cause looping.
• Fill Stitches (Tatami): Use for larger areas to avoid overly long stitches. Tatami fills provide texture and reduce fabric pull.
• Run Stitches: Best for outlines, small details, and lettering. Use a double run for added strength if needed.
• Use Split Satin: For wide satin areas, use the Split Satin feature to divide the satin into smaller segments, reducing the chance of looping and thread breaks.

5. Control Pull Compensation

• Adjust Pull Compensation: Pull compensation adjusts the stitch width to account for fabric pull during stitching. Increase pull compensation for stretchy fabrics to prevent gaps in the design.
• Settings: In Object Properties, adjust pull compensation settings. A value between 0.2mm and 0.4mm is typical, but it may vary depending on the fabric and design complexity.

6. Minimize Jumps and Trims

• Reduce Jumps: Jumps are thread movements between different design sections without stitching. Minimize jumps by carefully planning the stitch sequence.
• Travel Stitches: Use travel stitches (run stitches) to move between close elements instead of jumps. This ensures a continuous stitch flow and reduces the need for trimming.
• Avoid Unnecessary Trims: Excessive trims slow down the embroidery process and can cause thread breaks. Use the Auto Trim feature wisely, and disable it for small jumps if they don’t impact the design’s quality.

7. Adjust Stitch Direction

• Vary Stitch Angles: Adjust the stitch angles of different objects to avoid a uniform look and reduce fabric pull. For example, use a 45-degree angle for one object and a 90-degree angle for an adjacent object.
• Stitch Direction Tool: Use the Stitch Direction tool to set the direction manually. This control helps in achieving smoother stitch flow and better coverage.
• Compensate for Fabric Movement: On stretchy fabrics, angle the stitches to counteract the fabric’s natural movement, reducing distortion.

8. Use Feathered Edges

• Feathered Edge Effect: For a softer transition between colors or elements, use the Feathered Edge effect. This creates a gradual decrease in stitch density towards the edges of the object.
• Settings: In Object Properties, enable the Feathered Edge effect and adjust the settings to achieve a more natural blend.

9. Optimize Object Shapes

• Split Complex Shapes: Break down complex shapes into simpler elements. This allows you to control the stitch direction, density, and underlay more precisely.
• Smooth Curves: Use the Edit Shape Nodes tool to smooth out curves and reduce the number of nodes. This results in smoother stitch flow and reduces the risk of uneven stitching.

10. Use Auto Fabric Assistant

• Auto Fabric Setting: Use Wilcom’s Auto Fabric Assistant to automatically apply optimal settings for the chosen fabric type. This feature adjusts stitch density, underlay, and pull compensation based on the selected fabric.
• Fabric Presets: Choose from fabric presets like cotton, knit, denim, and others to quickly set up your design for the fabric you are using.

11. Test and Refine

• Stitch Simulation: Use the TrueView feature to preview the design and check for any issues with stitch flow.
• Slow Redraw: Use the Slow Redraw tool to simulate the stitching process. This helps you identify and fix any problems with the stitch sequence or flow.
• Test Sew: Always test the design on the actual fabric or a similar material to check how the design stitches out. Make adjustments as needed to optimize the stitch flow.

12. Save and Document Settings

• Save Settings as Styles: If you have optimized settings for a specific fabric or design type, save them as Styles in Wilcom. This allows you to quickly apply these settings to future designs.
• Document Changes: Keep a record of the changes you make during the optimization process. This helps in troubleshooting if issues arise during stitching.

Conclusion

Optimizing stitch flow in Wilcom Embroidery Studio involves a combination of careful planning, setting appropriate stitch types and densities, minimizing jumps and trims, and adjusting pull compensation. By varying stitch directions, using underlay stitches, and employing tools like Auto Fabric Assistant, you can create designs that stitch efficiently and look professional. Testing and refining the design on actual fabric is essential to ensure that the optimized settings produce the desired results.

Learn Optimize Wilcom stitch flow