Embroidery is fun. It turns simple art into thread magic. But many people face one big issue. Their design looks great on screen. Then it looks bad on the fabric. Lines shift. Shapes bend. Text gets messy. This is called distortion.

If you want to Convert Image to PES File, you must do it the right way. PES is a stitch file. It is used by Brother and Babylock machines. It does not read images like JPG or PNG. It reads stitch data. So you cannot just rename the file. You must digitize it with care.

In this guide, I will share simple steps. I will also share tips from real work experience. These steps will help you avoid distortion. Let’s start from the basics.

What Is a PES File?

A PES file is a stitch file. It tells the machine:

• Where to stitch
• How many stitches to use
• Which thread color to use
• When to stop or trim

It is not a picture file. It is a map made of stitches.

If your map is wrong, the result will be wrong.

Why Distortion Happens in Embroidery

Distortion is common. Even experts face it. But we know how to control it.

Here are the main reasons.

Fabric Pull and Push

Fabric moves. When the needle hits, the fabric pulls in. Stitches also push fabric out. This is called the push and pull effect.

If you do not plan for this, your circle will not be round.

Too Many Stitches

More stitches do not mean better quality. Too many stitches make fabric tight. The design shrinks or puckers.

Wrong Underlay

Underlay is the base stitch. It holds the top stitches. If the underlay is weak or wrong, the design shifts.

Poor Image Quality

If the image is blurry, the digitizing will be poor. Clean input gives clean output.

Step-by-Step Guide to Convert Image to PES Without Distortion

Now let us go step by step. Follow these simple rules.

Step 1: Choose a Clean and High-Quality Image

Start with a clear image.

Use Simple Designs

• Avoid tiny text
• Avoid very thin lines
• Avoid too many small details

Embroidery is not printing. It needs space.

Use High Resolution

A pixel image must be sharp. Blurry images cause guessing. Guessing causes mistakes.

If possible, use vector files like AI or EPS. They are the best.

Step 2: Prepare the Artwork

Before digitizing, fix the artwork.

Clean the Background

Remove unwanted parts. Keep only what you want to stitch.

Adjust Colors

Too many colors increase thread changes. Keep it simple.

Fix Thin Lines

Very thin lines will not stitch well. Make them thicker.

Step 3: Use Proper Digitizing Software

You need digitizing software. Examples include:

• Wilcom
• Hatch
• Brother PE-Design

Do not use normal graphic software. It will not create stitch data.

Step 4: Do Not Auto-Digitize Blindly

Many tools have auto-digitize. It looks easy. But it is risky.

I have tested auto tools many times. They create too many stitches. They miss path flow. They do not have a proper underlay.

Auto tools can be a starting point. But manual editing is a must.

Key Settings to Avoid Distortion

Now we go deeper. These are expert tips.

Push and Pull Compensation

This setting adjusts stitch width. It adds extra space to fight fabric pull.

When to Increase It

• On stretchy fabric
• On caps
• On thick designs

When to Keep It Low

• On stable fabric
• On small logos

Always test on scrap fabric first.

Choose the Right Stitch Type

Not all areas need the same stitch.

Satin Stitch

• Best for text
• Good for borders
• Clean and shiny

But do not use satin for very wide areas. It will snag.

Fill Stitch

• Good for large shapes
• Strong and stable

Set the right density. Too tight causes puckering.

Run Stitch

• Good for outlines
• Good for fine detail

Keep length balanced. Too long looks broken.

Set Correct Stitch Density

Density means how close stitches are.

Normal range is around 0.4 mm for fill. But this changes with fabric and thread.

Too tight = stiff design
Too loose = gaps in design

Test and adjust.

The Role of Underlay

The underlay is hidden but very important.

Why Underlay Matters

It:

• Holds fabric in place
• Lifts top stitches
• Reduces sinking

Without good underlay, distortion increases.

Types of Underlay

Edge Run

Runs along the edge. Good for satin.

Zigzag

Adds support under satin.

Tatami Underlay

Used under fill stitch.

Choose based on design shape.

Fabric Matters a Lot

You cannot use one setting for all fabrics.

Stable Fabrics

• Cotton
• Denim
• Canvas

Less distortion. Easy to stitch.

Stretch Fabrics

• T-shirts
• Jersey
• Lycra

High distortion risk. Use strong underlay and proper stabilizer.

Use the Right Stabilizer

The stabilizer supports fabric during stitching.

Cut-Away

Best for stretch fabric. It stays after stitching.

Tear-Away

Good for stable fabric. Easy to remove.

Water-Soluble

Used for delicate or special work.

Wrong stabilizer causes distortion even if digitizing is perfect.

Test Stitch Is Not Optional

I always tell clients this. Never skip test stitch.

Even big brands test every new design.

What to Check

• Are shapes correct?
• Is the text clear?
• Is fabric puckering?
• Are there gaps?

Fix in software. Then test again.

Resize with Care

Many people resize PES files directly on the machine.

This is risky.

When you resize too much:

• Density changes
• Stitch type changes
• Distortion increases

If resizing more than 10%, re-digitize the file.

Common Mistakes to Avoid

Let me share mistakes I see often.

Using JPG Directly

You cannot just load JPG into the machine. It must be digitized.

Ignoring Fabric Type

Each fabric behaves differently.

Overlapping Too Much

Too much overlap makes thick areas. Thick areas cause puckering.

Tiny Text

Text below 5 mm is risky. Use satin stitch. Adjust spacing.

Real-World Experience Tip

In my early days, I digitized a logo with thick fill and no proper underlay. On screen it looked perfect. On a polo shirt, it shrank and curved.

Why?

• High density
• No push compensation
• Wrong stabilizer

After fixing these, the same design stitched clean.

This is why experience matters. Small settings make a big change.

Why Professional Digitizing Helps

You can learn digitizing. But it takes time. Many brands trust experts to avoid waste.

Embroidery Digitizing Services in USA – Digitizing Buddy works with many fabric types. They test designs before delivery. They adjust push and pull. They set the correct density. This reduces distortion risk.

They also provide support and edits if needed. That builds trust.

When you work with experts, you save time, thread, and fabric.

Embroidery Digitizing Services in USA – Digitizing Buddy focuses on clean stitch paths. Clean path means smooth stitching. Smooth stitching means less stress on fabric.

That is how distortion is controlled.

Quality Checklist Before Final PES Export

Before you export the final PES file, check this list.

Design Check

• All shapes aligned
• No extra small gaps
• Proper overlap

Stitch Check

• Correct stitch type
• Balanced density
• Proper underlay

Fabric Plan

• Right stabilizer chosen
• Needle size correct
• Thread quality good

Test Result

• No puckering
• No broken thread
• Clean edges

If all is good, export to PES format.

How to Build Trust in Your Embroidery Work

If you sell embroidery or digitizing, trust is key.

Show Test Samples

Photos of real stitch outs build confidence.

Be Honest About Limits

Not all images work well in embroidery. Say it clearly.

Offer Revisions

Small edits help improve the final result.

Brands like Embroidery Digitizing Services in USA – Digitizing Buddy build long-term trust by offering support and clear communication.

Final Thoughts

Converting an image to a PES file without distortion is not hard. But it needs care.

Remember these key points:

• Start with clean artwork
• Use proper digitizing software
• Set correct density
• Add right underlay
• Adjust push and pull
• Choose correct stabilizer
• Always test stitch