We all have our favorite settings for creating lettering for different situations. For small lettering I like to decrease the density to 45 SPI and to add a single perpendicular running stitch as the underlay. For large lettering on a towel I like to use density of 65 SPI and a crosshatch underlay. You get the idea, and I am sure that you all have your own list of perfect combinations of settings that work just right for you. When you are creating your lettering using KPD Compositions you can save an unlimited amount of lettering styles, so that you can quickly and automatically call up the most perfect and personalized settings for the particular type of lettering you need.
Digitizing Lettering
When you run into a situation where the perfect font is not available it is necessary to digitize the lettering yourself. In this case the artwork you are working from is extremely important. If you are using the auto digitizing or semi-automatic function of your software to perform this function make sure that your artwork is 300 dpi or higher and the artwork is at least the same size of your finished embroidery or larger. The best method to use however is manual digitizing. The reason for this is when digitizing lettering the way in which your column stitches are divided up or branched is crucial for the best translation of the artwork into embroidery. When you are looking at an embroidery of something organic, such as a flower or a leaf variations from the original artwork are usually hard to discern, variations in lettering are almost always easy to spot. Everyone knows what lettering is supposed to look like and any variation from the norm is very obvious.
Size
The size of the lettering that you choose will also determine how you digitize the individual letters. You probably have noticed that just about every software manufacturer offer at least one small script and block font. The reason for this is that when you are sewing out lettering at .25 inches or smaller the rules that apply for embroidering larger lettering don't necessarily apply. Digitizing the corners of the lettering by inputting the individual stitches is the preferred method.
Fabric
When you decide to embroider the same lettering design on different fabrics you need to make sure that you create it for the most challenging fabric. for example if you are digitizing for denim and pique, digitize your lettering for the pique. You will end up with a higher stitch count but you will be assured that it will embroider well on both.
Pull compensation
If you are if you are digitizing lettering to sew out on fleece and twill, I would suggest that you digitize the design for twill and to automatically increase the pull compensation for the fleece application.
Underlay
As in the case of pull compensation I would digitize the lettering with a single center run stitch underlay and then as I increased it in size add first an edge run and then at over .75 inches also add a zig-zag underlay.
Visually correct adjustments
Distorting keyboard lettering
If you look at the example of a standard computer font "EGGSALAD" you will notice that the rounded letters "G" and "S" are slightly larger than the others so that they will appear o b the same size when the word is viewed as a whole. The example of the same word in small embroidered lettering takes the rule a little further, not only is the "G" and "S" larger but so are the letters that have horizontal column stitches such as the "D" and the "E"
Many logos utilize a standard font with only minor changes to either the first letter or letters within the wording. Before you decide to digitize the lettering portion of the design see if you can use the lettering portion of your software to create the lettering and then select the individual letters that need to be altered and adjust them one at a time.
Lettering is just like every other portion of your design, you need to follow all of the same rules as you would when digitizing any design. If you start with good artwork, whether you decide to use keyboard lettering or digitize the lettering from scratch while taking fabric, and sizing limitations in mind your results will be successful.