Table of Contents
- Primer: What this merge achieves—and when to use it
- Prep: Files, tools, and a clean canvas
- Setup: Hoops, visibility, and smart placement
- Operation: Merge, resize, split, and erase (the clean-stitch method)
- Quality Checks: How to know it’s truly clean
- Results & Handoff: Fit to 5x7 and save your PES
- Troubleshooting & Recovery: Fixes for common hiccups
- From the comments: Quick answers to common questions
Video reference: “How To Merge Designs In SewWhat-Pro” by Dani and Gypsy
If you’ve ever layered a character over a birthday number and ended up with a lumpy sew-out or broken needles, this guide is your new best friend. We’ll merge two designs in SewWhat-Pro, erase the hidden satin where they overlap, fit the result to a 5x7 hoop, and save one clean file—ready to stitch.
What you’ll learn
- The clean-stitch method: merge, split, and erase under-stitches for a smooth finish
- How to resize individual parts vs. the whole composition—and why order matters
- The fastest way to center and fit your design to a 5x7 hoop without distortion
- Practical checkpoints to confirm you didn’t leave any hidden stitches behind
Primer: What this merge achieves—and when to use it Merging lets you combine two separate embroidery designs (for example, an appliqué number and a character) into a single, stitch-ready file. The key to a professional result is removing the satin stitches where the top design overlaps the bottom. That way, your machine sews through one satin at a time—not a dense, stacked mess that strains the needle and leaves a thick ridge.
Use this workflow when:
- You’re building a custom birthday number (e.g., an appliqué 5 with a character over it)
- You want the character to look seamlessly integrated—no doubled satin borders
- You need the final composition to fit a specific hoop (here: 5x7)
Outcome expectations:
- A single PES file containing both designs
- Overlapping satin from the number is erased under the character
- Final dimensions fit within 5.0 inches in the 5x7 hoop
Quick check: Your base number should be an appliqué style with a hollow interior—perfect for adding fabric. A solid number works against this technique and creates excess density.
Prep: Files, tools, and a clean canvas What you need
- SewWhat-Pro installed on your computer
- Two embroidery files in a compatible format (PES shown here):
- An appliqué number file (e.g., “Number 5.pes”)
- A character file (e.g., a Mulan character PES)
- A 5x7 hoop as the target size in software
From the comments: Several readers asked where to get designs and typical prices. One reply shared that designs are purchased online from various sites, often around $3–$5; fonts or number sets can be around $8–$15. Another comment noted they use SewWhat-Pro exclusively based on a recommendation.
Watch out: Choose an appliqué number with an open center. Solid numbers add density and complicate overlap cleanup.
Decision point: USB vs. direct use
- If you plan to stitch right away: you’ll still save your merged PES to USB at the end.
- If you’re building a library first: organize designs on your computer; you can edit later and then save to USB.
Community tip: One commenter confirmed a simple flow—buy files online, download to your computer, edit in SewWhat-Pro, then save to USB for the machine. magnetic embroidery hoops
Prep checklist
- Appliqué number PES on your computer
- Character PES on your computer
- SewWhat-Pro opens to a clean canvas
- You know which hoop you’re targeting (5x7 in this guide)
Setup: Hoops, visibility, and smart placement 1) Open the number and set hoop size
- File > Open > select your number file (e.g., “Number 5.pes”).
- Set the hoop to 5x7 (Brother/BabyLock PES type). Grid lines can help visualize alignment.
- The number appears large—that’s OK; editing large is easier.
Quick check: Confirm you’re seeing an appliqué number with a hollow interior and grid lines if you find them helpful.
2) Merge the character and plan overlaps
- File > Merge > select the character file.
- Drag it into place over the number.
- Strategy matters: avoid positioning that forces lots of intricate overlap zones. Aim for one or two simple contact points instead of many tight corners.
Pro tip: Align bottoms using the grid; it’s easier to judge balance and keep the character grounded visually.
Setup checklist
- Number loaded and hoop set to 5x7
- Character merged onto the number
- Overlap areas chosen to minimize cleanup later
Operation: Merge, resize, split, and erase (the clean-stitch method) Step 1 — Resize the character slightly
- Select only the character (make sure the number is not selected).
- Tools > Resize Pattern > set width/height to 95%.
- Reposition over the number, aligning the bottom edge.
Why this order: Resizing the character first helps you choose more efficient overlap zones and prevents rework after stitch edits.
Quick check: Character looks proportionate and avoids dense internal corners of the number.
Step 2 — Prepare for stitch-level editing
- Temporarily move the character toward the middle of the screen (you can re-center later). This gives you space to zoom and edit.
- Edit > Split Pattern to separate the designs into independently editable parts.
- Remove grid lines (View > Grid Lines) if they’re visually distracting.
Outcome: Number and character are independent for precision editing.
Watch out: Do not stack satin over satin. Layering satin stitches creates a “hot mess,” stresses the machine, and leaves a bump.
Step 3 — Target only the number’s satin - In the split interface, use Select Colors and click the number’s satin color (shown as red). Everything else should gray out—so you only erase the red satin from the number.
Step 4 — Erase the overlapping stitches cleanly
- Choose the eraser tool and select the next-to-largest size for better control.
- Zoom to 1000% for clarity.
- Carefully erase the red stitches where the character will cover the number. Work slowly; going too fast can leave tiny red fragments.
- For tight areas, start with controlled strokes, then zoom out slightly and switch to broader passes to clear the rest.
- Repeat at each overlap zone until all underlying red is fully removed.
Quick check: No red satin remains under the character. Inspect edges closely—any leftover red will still stitch.
Pro tip: If you slip and remove something unintended, use Undo immediately. Zoom in again and re-approach slowly. brother 5x7 magnetic hoop
Step 5 — Commit erasures and re-center
- Click Close to exit the split interface.
- When prompted, confirm Yes to perform pending erasures—this saves your careful edits.
- Select both the number and the character.
- Click Center pattern in hoop to snap everything back to the hoop center.
Operation checklist
- Character resized and repositioned
- Patterns split and grid lines hidden (if preferred)
- Only the number’s red satin targeted for erasure
- All red under-stitches removed
- Edits committed and design centered
Quality Checks: How to know it’s truly clean
- Visual sweep at 1000%: Inspect every contact point between the character and number; no red stitch segments should remain.
- Visual sweep at normal zoom: The silhouette should look seamless without doubled borders.
- Hoop boundary check: The combined design should still sit comfortably within the 5x7 hoop area after re-centering.
Quick check: If you see any red bits peeking where the character overlays, return to split mode and erase them now. It’s faster than fixing a dense spot at the machine.
Results & Handoff: Fit to 5x7 and save your PES Final resizing to fit the hoop
- Toggle grid lines back on if you prefer (View > Grid Lines).
- Select both components and go to Tools > Resize Pattern.
- Make incremental adjustments and watch the dimensions. In the example workflow:
- Try 90%, then Undo if too small.
- Try 95%; check the readout.
- Finally, 98% landed at 4.98 inches—just under the 5.0-inch limit for this hoop.
Why incremental: Small nudges prevent distortion and help you land just inside the hoop maximum.
Save as a clean, single file
- File > Save As
- Choose a descriptive name (e.g., “Number5-5x7.pes”).
- This produces one merged file with all your edits applied—ready for the machine.
From the comments: A helpful note confirms the handoff: download designs to your computer, edit in SewWhat-Pro, then save to a USB and plug it into your machine. mighty hoops for brother
Pro tip: Your software workflow is the same regardless of your physical hoop style—standard or magnetic—because all the cleanup happens in the file. embroidery hoops magnetic
Troubleshooting & Recovery: Fixes for common hiccups Symptom: Bulky ridge where character crosses the number
- Likely cause: The number’s satin under the character wasn’t erased.
- Fix: Return to Edit > Split Pattern, select the number’s satin color, and erase remaining overlaps at 1000% zoom.
Symptom: Needle struggles or breaks at overlap
- Likely cause: Two satin borders stacked; density too high.
- Fix: Same as above—remove the under-stitch areas from the number.
Symptom: Character or number moved off-center after resizing
- Likely cause: Resizing after centering.
- Fix: Select both components and click Center pattern in hoop again.
Symptom: Overall design too big for 5x7
- Likely cause: Insufficient resizing after merge.
- Fix: Select all and use Tools > Resize Pattern. Take incremental steps (e.g., around 98% landed at 4.98 inches in the example). brother embroidery machine magnetic hoop
Symptom: Eraser is imprecise
- Likely cause: Using the largest eraser size or low zoom.
- Fix: Use the next-to-largest eraser at 1000% zoom, make a clean cut, zoom out slightly, and finish with broader strokes.
Quick isolation tests
- Toggle grid lines off if they distract from stitch edges during erasure.
- Select colors to ensure only the number’s satin is active before erasing.
From the comments: Quick answers to common questions Q: Do I need software to get designs onto my machine? A: One commenter shared this flow: buy and download to your computer, edit in SewWhat-Pro, then save to a USB for your machine. dime snap hoop
Q: Where do you buy designs and what do they cost? A: A shared experience: designs from various online shops, often $3–$5; fonts or number sets can be around $8–$15. hoop master embroidery hooping station
Q: Can SewWhat-Pro do full digitizing? A: This specific question wasn’t answered in the thread.
Q: I’m new—any moral support? A: Multiple encouraging replies thanked the tutorial and confirmed the steps were easy to follow; you’ve got this. magnetic hoop for brother se1900