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I'm actually very very interested in this opinionated approach to patch design -- can you tell me more? Or refer me to some useful design guides? I can just google something random too, but it sounds like you might know / have some good resources already

The term you'll want to search for is "digitizing". It's roughly the embroidery equivalent of CAM design in CNC manufacturing.

Depending on how much time you have, this video[0] is a decent in-depth overview[1] of the various ins and outs of embroidery patch digitizing. I'd give it a watch while you're on a walk or something.

[0] https://www.youtube.com/live/jATHlfz8mtM?si=Lvw-ZTq8tmLg9ij-

[1] Heh, "in-depth overview" sounds like a total oxymoron. Hopefully you get what I meant!

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