OFM vs DST vs EXP in Melco DesignShop 11: Stop Losing Trims, Colors, and Sanity When You Open Embroidery Files

The "Alphabet Soup" of Embroidery Files: A Master Guide to Stopping Production Disasters

If you have ever loaded a customer-supplied file, hit "Start," and watched in horror as your machine stitched a tangled mess of jump stitches across a $50 hoodie, you know the specific sinking feeling I’m talking about. It is the sound of profit vanishing.

As educators, we see this panic daily. But here is the truth: The machine isn't broken. The file isn't "corrupt." It is simply speaking a language you haven't translated yet.

This guide rebuilds the workflow based on Melco DesignShop v11, but the principles apply universally. We will move beyond button-pushing into process engineering—teaching you how to "read" a file before you wreck a garment, how to safely navigate the settings, and when to stop fighting your tools and upgrade your workflow.

The Mental Model: "The Architect" vs. "The GPS"

Embroidery formats look like a random scramble of letters (OFM, EXP, DST), but to a professional, they fall into two distinct cognitive buckets. Understanding this distinction is the only way to edit safely.

1. The Architect: Wireframe Files (OFM, EMB)

Think of an OFM file as an Architect’s Blueprint. It has "brains."

• Object-Based: It knows that a circle is a "Circle Object" with a specific fill pattern.
• Calculative: If you scale it up 20%, it calculates new stitches to maintain density.
• Data-Rich: It stores color data, special settings, and crucial notes.

2. The GPS: Stitch Files (DST, EXP)

Think of a DST file as a GPS route log. It has no brain; it only has coordinates.

• Coordinate-Based: It says "Move needle X+1mm, Y+1mm, Drop Needle." It does not know it is drawing a circle.
• Static: If you scale it up 20%, the stitches just get farther apart (gaps appear). If you scale down, they overlap (thread breaks/needle deflection).
• Color-Blind: It usually defaults to random colors because it only knows "Stop for color change," not "Switch to Royal Blue."

The Golden Rule of Safety:

Never treat a Stitch File (GPS) like a Wireframe (Architect). If you need to resize a design by more than 10-15%, do not force a DST file to do it. You risk needle breakage and ruined fabric. Go back to the digitizer.

Wireframe OFM: The "Safety Net" Workflow

In the tutorial, we see the instructor manipulating a cupcake design in OFM format. This is your "Working File." This is where you are safest.

What you can control here (Sensory Check):

• Visual: You see "nodes" (little squares) around shapes. This means you can reshape the design.
• Tactile: You can change densities. If a fill looks too loose on screen, you can tighten it for better coverage on textured fabrics like pique polo.

The Secret Weapon: Embedded Notes

The difference between a hobbyist and a production manager is the Notes Tab. When you save an OFM, you aren't just saving stitches; you are saving your experience.

Write this down in every file:

1. Fabric: (e.g., Heavy Canvas Apron).
2. Stabilizer Recipe: (e.g., 2 layers of 2.5oz Cutaway).
3. Needle info: (e.g., 75/11 Sharp).
4. Hoop used: (e.g., 5.5" Round Standard).

Pro Tip: If you run a melco embroidery machine, utilizing the native OFM notes allows any operator on any shift to replicate the job perfectly without guessing.

Prep Checklist: The "Pre-Flight" Safety Check

• Identify the File Type: Look at the Project Tree. Do you see "Wireframe" icons or "Expanded Data"?
• The "Save As" Rule: Immediately save a copy (e.g., Design_V2_Edited.ofm). Never over-write the customer's original file.
• Consumable Check: Do you have the right needles? (Check for burrs by running the needle tip gently over your fingernail—if it scratches, trash it).
• Stabilizer Decision: If the design is dense (>15,000 stitches) and the fabric stretches, do not use Tearaway. Use Cutaway.

The "Expanded Data" Panic (DST/EXP)

When the video opens the DST version, the "Wireframe" objects vanish, replaced by a scary list called Expanded Data.

• Don't Panic: The design is fine. It will sew perfectly.
• The Limitation: You cannot easily change underlay or pull compensation.
• The Display Trick: DST files often show neon green or random colors. This does not affect the sew-out. The machine will sew whatever thread cone you put on needle #1.

The "Missing Trim" Nightmare: Why You Have Connector Lines

This is the most common reason for 1-star reviews on digitized files. You open a file, and there are ugly zig-zag lines connecting every letter.

The Physics of the Problem

Old formats (like DST/EXP) sometimes don’t have a specific command for "Cut Thread." Instead, they use a code: "Jump, Jump, Jump." If your software (Melco DesignShop) is waiting for a "Trim" command, but the file is whispering "Jump, Jump, Jump," the software ignores it and draws a line.

The Fix (Melco DesignShop v11 specific):

1. Go to Tools > Options.
2. Select the Expanded Open and Save tab.
3. Find Jump stitches for a trim.
4. Change the value to 3.

Why 3? (The Industry Sweet Spot) Most digitizers standardly input 3 jump commands to signal a trim.

• If set to 0 (Disabled): You get connector lines (no trims).
• If set to 1: You risk the machine trimming in the middle of a tatami fill or a satin column, causing a "bird's nest" of thread underneath. Keep it at 3 for safety.

Crucial Step: You must Close and Re-Open the file for this setting to take effect. It is a translation setting, not an editing tool.

Setup Checklist: Diagnosing Trims

• Visual: Do you see connector lines crossing open fabric?
• Action: Check your "Jump stitches for a trim" setting. Is it at 3?
• Verify: Re-open the file. Did the lines vanish?
• Sensory Confirm: When running the machine, listen. A proper trim sounds like a distinct mechanical ka-chunk followed by silence as the pantograph moves. If you hear a swish-swish sound of thread dragging, hit Stop.

"Save As": Securing Your Work

The dropdown menu in File > Save As is your gateway to compatibility.

• OFM: Save this for yourself (The Master Record).
• DST/EXP: Save this only to send to the machine.
• Raster (PNG): Save this for customer approval.

Raster vs. Vector: Preventing "Grainy" Proofs

When sending a proof to a client:

• Raster (PNG/JPG): Made of pixels. If you zoom in, it blurs. Good for email proofs.
• Vector (SVG): Made of math. Infinite zoom. Great for vinyl cutters or screen print separations.

The SVG Warning: Embroidery software is notoriously bad at exporting SVGs for other uses. If you see points shifting or weird loops, it’s a translation error. For customer visual approval, stick to PNG with a transparent background.

The "Hybrid" Trick: Colorizing Expanded Files

You really want to save notes, but you only have a DST? The instructor shows a vital trick: You can save a DST inside an OFM wrapper.

1. Open the DST (Expanded Data).
2. Manually assign the correct colors in the software so it looks right.
3. Add your Production Notes (Stabilizer, Hoop, etc.).
4. Save As > OFM.

It is still "dumb" expanded data (you can't resize it safely), but it now remembers your colors and notes. This is essential for repeat orders.

Production Tip: When managing inventory, use the OFM notes to record the specific embroidery hoops for melco you used (e.g., "15cm Hoop"). Next year, you won't waste time guessing which hoop fits.

Scaling Up: From Software to Hardware Efficiency

We have spent a lot of time fixing files to save time. But what about the physical time? If you fix a file in 2 minutes but spend 10 minutes fighting to hoop a thick Carhartt jacket, your efficiency is dead.

Identify Your Bottleneck:

• The Symptom: "Hoop Burn" (shiny rings on fabric) or crooked placement because you are struggling to tighten simple screws on thick seams.
• The Criteria: Are you doing more than 20 items a week? Are you fighting with wrist pain?
• The Solution (Level up): This is where professionals switch to a magnetic embroidery hoop.
  • Speed: It snaps on/off in seconds. No screws.
  • Quality: No friction rings means no hoop burn on delicate performance wear.
  • Production: When using a hooping station for embroidery, magnetic hoops allow for consistent, rapid-fire placement that standard hoops cannot match.

Warning: Magnetic Safety
Magnetic hoops use industrial-grade neodymium magnets.
* Pinch Hazard: They snap together with enough force to crush fingers. Handle by the edges.
* Pacemakers: Keep these hoops at least 12 inches away from anyone with a pacemaker or insulin pump.

Decision Tree: The "Seconds to Decision" Matrix

Don't guess. Follow this path when you receive a file.

Operation Checklist: The Final "Go/No-Go"

Before you press the green button:

1. File Reality Check: Did I verify if this is Wireframe or Expanded? (Manage expectations).
2. Trim Logic: Did I confirm the connector lines are gone?
3. Physical/Digital Match: Does the hoop I selected in the software match the actual hoop on the machine? (Prevents needle-hitting-plastic disaster).
4. Consumables: is the correct stabilizer loaded?
   • Hidden Item: Do you have temporary spray adhesive or a water-soluble pen for marking?
5. Thread Path: Is the thread creating a "floss-like" resistance when pulled? (Tension check).

Embroidery is a game of variables. By locking down your file format knowledge, you eliminate the digital variables. By upgrading to tools like magnetic embroidery hoops and capable machines like SEWTECH, you eliminate the physical variables.

Control the variables, and you control the profit. Now, go save that file (as an OFM).

FAQ

• Q: In Melco DesignShop v11, how do I stop connector lines between letters when opening a DST/EXP embroidery file?
  A: Set “Jump stitches for a trim” to 3, then close and re-open the DST/EXP file.
  • Go to Tools > Options > Expanded Open and Save.
  • Find “Jump stitches for a trim” and set it to 3 (industry sweet spot).
  • Close the file completely and re-open it (the setting only applies on open).
  • Success check: the ugly zig-zag connector lines disappear on screen, and the machine trim sounds like a clean “ka-chunk.”
  • If it still fails: confirm the file is truly DST/EXP (expanded data) and re-check the setting did not revert.
• Q: In Melco DesignShop v11, what is the safe resize limit for a DST embroidery file to avoid gaps, overlaps, and needle breaks?
  A: Treat DST/EXP as “sew-as-is” and avoid resizing more than 10–15%; if the change is bigger, request the original OFM/EMB or re-digitizing.
  • Identify the format first: wireframe (OFM/EMB) is safe to re-calculate; expanded (DST/EXP) is not.
  • Stop any plan to resize a DST/EXP by >20% (this is where production disasters commonly happen).
  • Save a new version name before changes (example: Design_V2_Edited) to protect the customer original.
  • Success check: after resizing a wireframe file, stitch density still looks even and coverage remains consistent on-screen.
  • If it still fails: go back to the digitizer for a proper size or request a true wireframe file.
• Q: In Melco DesignShop v11, how can a shop save production notes and correct thread colors when the customer only sends a DST file?
  A: Wrap the DST inside an OFM by colorizing it, adding notes, and using Save As > OFM (the stitch data stays expanded, but the job becomes repeatable).
  • Open the DST (it will show as expanded data).
  • Manually assign thread colors so the preview matches the intended sew-out.
  • Add production notes (fabric, stabilizer recipe, needle, hoop used) so any operator can repeat the job.
  • Save As > OFM for your internal “master record,” and export DST/EXP only for the machine.
  • Success check: re-opening the OFM shows the same assigned colors and your notes are still present.
  • If it still fails: remember this does not make the design safely resizable—treat it as expanded data.
• Q: In production embroidery, how do I check needle condition before a run to prevent thread breaks and ruined garments?
  A: Replace any needle that feels rough—run the needle tip lightly over a fingernail and trash it if it scratches.
  • Pull the needle and do the fingernail “burr test” before loading a high-value garment.
  • Swap to the needle type/size specified in the job notes whenever possible (a safe starting point is to follow the machine manual).
  • Save needle info in the file notes so the next operator does not guess.
  • Success check: the needle tip feels smooth on the fingernail and stitching runs without sudden thread shredding.
  • If it still fails: stop and re-check thread path and tension feel (“floss-like” resistance), then test sew on scrap.
• Q: In machine embroidery, what stabilizer choice prevents distortion when a design is dense (over 15,000 stitches) on stretchy fabric?
  A: Use cutaway stabilizer instead of tearaway when the design is dense (>15,000 stitches) and the fabric stretches.
  • Identify risk factors: high stitch count plus stretchy fabric is a common distortion combo.
  • Choose cutaway and document the “stabilizer recipe” in the working file notes for repeat orders.
  • Avoid tearaway in this scenario because it may not support the garment through the full sew cycle.
  • Success check: after sewing, the fabric lies flat without rippling and the design edges stay clean.
  • If it still fails: add more support (often an extra layer helps) and run a test sew-out before the real garment.
• Q: In embroidery machine setup, how do I confirm the hoop selected in software matches the physical hoop to avoid needle-hitting-plastic disasters?
  A: Always match the software hoop selection to the actual hoop on the machine before pressing Start.
  • Verify the hoop name/size in the software setup screen before sending or starting the job.
  • Physically confirm the installed hoop/frame matches that selection (don’t rely on memory across shifts).
  • Stop immediately if the design boundary looks too close to the hoop edge.
  • Success check: the needle path stays safely inside the hoop opening during the first few stitches.
  • If it still fails: re-select the correct hoop in software and re-check placement before restarting.
• Q: What are the key safety rules for using magnetic embroidery hoops in a production shop to prevent finger injuries and medical device risks?
  A: Treat magnetic hoops as pinch hazards and keep them at least 12 inches away from pacemakers or insulin pumps.
  • Handle the magnetic hoop by the edges and let it close under control—do not let it snap.
  • Keep fingers out of the closing gap; magnets can crush fingertips.
  • Enforce a clear bench area so the top ring cannot jump to metal tools.
  • Success check: the hoop closes smoothly without sudden snapping, and operators keep hands clear every cycle.
  • If it still fails: stop using the magnetic hoop until the team is retrained on safe handling and spacing rules.