Wilcom TrueSizer Tutorial: Convert, Preview, and Quality-Check Embroidery Files

Watch the video: “Wilcom TrueSizer: Convert and Preview Embroidery Designs” by Burley Sew

If you convert designs or run a small embroidery shop, wasted stitch-outs are costly. This guide shows how the free Wilcom TrueSizer helps you preview quality, simulate stitches, and export to PES—all before you ever hoop fabric.

What you’ll learn

• How to download and open designs in Wilcom TrueSizer

• When to use the production worksheet, TrueView, and stitch-out simulation

• How to export a DST to PES (including setting PES version and 100×100mm hoop)

• What to expect when you stitch the PES vs. the original DST on a Brother SE-400

Understanding Wilcom TrueSizer: Your Free Embroidery Companion

What is TrueSizer? TrueSizer is a free Wilcom tool for opening, inspecting, and converting embroidery designs. The desktop app offers more features than the web version, and this tutorial focuses on its strengths for post-production quality checks and format conversion rather than design editing.

Why File Conversion Matters in Embroidery Even the best stitch files need the right format for your machine. In the video, a DST file is opened and saved as a PES for a Brother machine. The side-by-side stitch test at the end shows that both versions look nearly identical on fabric, which is reassuring if you’re converting for a production run. When you’re selecting hoop sizes, remember that 100×100mm is roughly a 4-inch square—common on entry-level machines with a brother 4x4 embroidery hoop.

Getting Started: Download and Installation Guide

Choosing Between Web and Desktop Versions Wilcom offers TrueSizer in two flavors: an in-browser web app and a desktop application for PC. The video notes both are free, but the desktop app has more features for this workflow. If you need richer preview tools and printing, the desktop route is the safer bet.

Navigating the Sign-Up Process To download the desktop version, you’ll create an account and complete a detailed form. The host mentions the sign-up kicked back once until all questions were filled out—so take a minute to complete every required field before submitting.

Installation Tips Run the installer, launch the app, and you’ll see a splash screen, then the main interface with a grid. From there, you’re ready to bring in your first design.

Pro tip If you’re unsure which edition to start with, install the desktop version first. You’ll gain access to TrueView, production worksheets, and stitch-out simulation showcased in the video.

Opening and Analyzing Your Embroidery Designs

Loading Various File Formats (e.g., DST) Open your file via File > Open. Make sure to switch the file type filter to the format you need (the tutorial uses DST) so your file appears in the dialog. Once selected, it loads onto the grid.

Quick check If nothing shows up, confirm the file type filter matches your design format and that you’re in the correct folder on your computer. When your goal is to convert for a specific machine brand, it helps to know that TrueSizer supports many common formats used across brands, including those for a brother embroidery machine.

Deciphering the Production Worksheet With the object selected, go to File > Print > Print Preview. TrueSizer generates a production worksheet summarizing stitch counts, color changes, minimum stitch length, and size. This is ideal for shop notes and verifying the design’s scope before stepping to fabric.

Watch out TrueSizer includes tools like scaling and rotation, but in the video, applying these introduced distortion to the spiderweb design. If you notice similar issues, make adjustments in your digitizing software instead, and rely on TrueSizer for inspection and conversion.

From the comments A viewer asked about merging multiple patterns. The video does not demonstrate merging, and it isn’t covered by the presenter’s workflow here. If you need to combine elements, you may want a full digitizing program; TrueSizer is positioned as a post-production tool.

Advanced Pre-Stitching Checks with TrueSizer

Visualizing Stitches with TrueView TrueView renders stitches realistically so you can zoom in, scrutinize overlaps, and gauge density. The host uses it to spot areas that might stitch “sloppy” or looser than desired. You can even enable display options to see needle penetrations, giving a clear sense of how the stitch path will behave on fabric.

Pro tip Zoom in along edges and dense intersections to look for snags, loose coverage, or overly tight packs. The earlier you see issues, the less likely you’ll waste stabilizer and thread. If you plan to run multiples, this preview is worth its weight in bobbins. A thoughtful preflight check here pairs well with choosing the right accessory, such as stabilizers or well-fitted embroidery machine hoops.

Simulating the Stitch-Out Process Use View > Stitch Out to watch the design form on-screen. This second “set of eyes” reveals sequencing and travel paths and can help you confirm the build order looks logical. The presenter uses simulation as one more safety net before exporting.

Quick check Does the simulated sequence match your expectations (e.g., center-out or light-to-dark where appropriate)? If anything looks off, return to your source file in your digitizer to adjust sequencing; the video does not show redesign inside TrueSizer.

Converting and Exporting for Your Machine (DST to PES)

Selecting the Right PES Version and Hoop Size When ready to convert, choose File > Save As, select PES (the tutorial specifies “PES Brother 10.0”), and confirm the PES version in the dialog. Set the hoop size to 100×100mm (approximately a 4-inch hoop). The presenter’s Brother SE-400 recognizes both DST and PES, but the PES shows a thumbnail preview on-machine, which is user-friendly.

Practical Export Demonstration The video demonstrates saving the DST as PES and then moving the file to a machine for a stitch test. No extra steps are required—just pick the format, confirm the version and hoop, and save. Note that the tutorial does not cover converting from or to formats outside of what’s shown (e.g., it doesn’t demonstrate PED or XXX). When you’re working in a 4-inch field, the classic pairing is a design built for a brother 4x4 embroidery hoop, whereas larger designs may require different hoops on compatible machines. The video does not specify larger hoop tests.

From the comments

• Can TrueSizer digitize? The video doesn’t cover digitizing or TrueSizer Pro features; it positions TrueSizer as a viewing/conversion tool.

• Can you convert from JPG/PNG to stitch? That process—turning an image into stitches—requires digitizing software, not shown in this tutorial.

• Can you convert PED or XXX? The tutorial demonstrates DST to PES only; other conversions aren’t shown.

From Screen to Fabric: Stitching and Comparison

Transferring to Your Brother SE-400 Copy the converted PES (and the original DST) to a USB drive, plug into the Brother SE-400, and navigate to your files. On the SE-400 screen, PES shows a thumbnail preview, while DST appears as a file name. The presenter selects the spiderweb design and prepares the stitch-out.

Pro tip Preview thumbnails can be a real time-saver on the machine. Even if your model reads multiple formats, pick the one that provides the clearest on-screen preview and compatible hoop options. If you tend to switch hoops often, keeping a simple list of your machine’s supported sizes—like 4-inch square—helps prevent mix-ups. For those who swap between standard hoops and accessories like a brother magnetic hoop, double-check alignment and centering before pressing start.

Side-by-Side Quality Assessment With white thread on black fabric, the host stitches the DST and the converted PES. The takeaway: results are “pretty close,” looking nearly identical. That’s the confidence TrueSizer aims to deliver—preview, simulate, export, and stitch with minimal surprises.

Watch out If your stitch-out looks unexpectedly loose or “webby,” revisit TrueView to inspect overlaps and density. The presenter mentions noticing looseness in a spiderweb design (uncertain whether due to software, machine, or design specifics). If you see similar behavior, consider revising the original file in a digitizer before production. For larger designs, confirm you’ve picked the right hoop on the machine. While this demo sticks to a 4-inch field, some users keep multiple sizes, from a compact field to something like a brother 5x7 hoop, depending on their model.

Troubleshooting and FAQs from the Community

Why can’t I open my files in TrueSizer? One commenter noted they “downloaded free sizer” but couldn’t open their files. In the tutorial, the key step is changing the file type filter in the Open dialog (e.g., DST). If the design still won’t appear, the video doesn’t specify additional causes; check the file format is supported and not corrupted.

How is “Save As” different from “Convert”? A viewer asked whether the tutorial actually converted or just “saved as.” In TrueSizer, conversion happens when you Save As a different machine format (e.g., DST to PES). That’s the conversion step shown on screen.

Can TrueSizer digitize or vectorize images? Questions about digitizing (including “vectorizing a bitmap”) came up. The video does not demonstrate digitizing; it focuses on inspection, simulation, and format export. If you need to turn images into stitches, use a digitizing program; this tutorial doesn’t cover it.

Why do I get a “design lies outside the maximum stitching area” message? A commenter mentioned an error converting from PES to JEF. The video does not cover PES→JEF or that error. Generally, ensure your design’s size and hoop selection match the target machine’s max area. In the tutorial’s export, 100×100mm was selected for a 4-inch field on the target machine.

Does TrueSizer merge designs? Merging multiple patterns isn’t shown in the tutorial, and the presenter doesn’t use that workflow here. Use a digitizer if you need to combine or significantly edit designs.

Can TrueSizer scale a design slightly? The presenter cautions that scaling and rotation distorted the spiderweb test. If you must resize, consider doing it in a digitizing program and then return to TrueSizer for inspection and export.

Will it open DST files from my digitizer? This tutorial opens a DST (spiderweb2.dst) successfully and proceeds to inspection and export. If your DST won’t open, confirm the file isn’t damaged and that you’ve selected DST in the filter.

Does TrueSizer work with Janome’s JEF or other formats? The video focuses on DST→PES. It does not demonstrate JEF or other brand-specific formats. Check TrueSizer’s format list within the Save As dialog on your system.

Workflow recap you can trust

• Use the desktop TrueSizer for the richest toolset.

• Open your DST, generate a production worksheet, and review stitch counts and dimensions.

• Inspect with TrueView and simulate the stitch-out to sanity-check flow.

• Save As PES (v10.0 in the demo) and set the hoop to 100×100mm.

• Stitch and compare—this spiderweb looked nearly identical across DST and PES.

From the comments: useful nuggets

• A few viewers thanked the host and noted they learned new details even as current users.

• Multiple questions asked about digitizing or image→stitch conversion; those aren’t demonstrated here.

• One viewer highlighted loud background music versus narration—if you’re recording your own tutorials, keep audio mix in mind for clarity.

Shop-floor checklist

• Confirm the file filter matches your design format before opening.

• Print a production worksheet with stitch counts and dimensions.

• Inspect with TrueView, then run a stitch-out simulation.

• Save As the format your machine prefers; set PES version and hoop size explicitly.

• On-machine, pick the file with the clearest preview.

Final thought TrueSizer excels as a free, post-production lens: preview, simulate, and export. That’s how you cut down on test stitch-outs and go to fabric with confidence. If your business relies on fast, reliable turnarounds—especially on compact fields like the 4-inch—this workflow can be the difference between guessing and knowing. For those who kit out their stations with accessories such as magnetic embroidery hoops or maintain an assortment of brother hoops, dialing in the digital checks first ensures what you see on screen is what you’ll stitch.

Gear context The stitch test in the video runs on a Brother SE-400. It recognizes both DST and PES, but PES offers a thumbnail preview on-screen, which makes selection easier. If you work across multiple machines or formats, keep a simple chart of your most-used fields and hoops—especially handy if you shuttle designs between different models within the brother embroidery machine family.

Optional accessories and field planning While the video doesn’t use them, many shops maintain a range of hoops and frames for specific textiles and placements. If you frequently switch between knits and wovens, or between hats and flats, planning your hoop inventory (standard and specialty) can save time on setup—ranging from core 4-inch squares to broader fields. If you’re frequently swapping to alternative holding systems, ensure your machine’s settings and design boundaries align before pressing start. Many embroiderers who manage varied placements keep both standard frames and add-ons, though the tutorial focuses on the standard 100×100mm selection rather than add-on systems like a brother magnetic hoop.

Production confidence, one preview at a time By leaning on TrueView and stitch-out simulation, you can identify issues early. Once you’re satisfied, exporting to PES (with the correct version and hoop size) makes the machine step feel anticlimactic—in the best way. The result, as shown in the side-by-side spiderweb, is a stitch-out that’s “pretty close,” essentially identical by eye in this test.

Next steps

• Use TrueView to create a standardized preflight check for every job.

• Print production worksheets and attach them to job bags.

• Export in the format that provides the best on-machine preview.

• Keep your hoop map handy—especially if you switch between fields beyond the 4-inch, such as those compatible with a brother 5x7 hoop.

If your shop spans multiple hoop sizes, maintain a labeled drawer system or board: small 4-inch fields in one section, larger fields in another. For teams juggling frequent changeovers, clearly labeling stabilizer type and hoop pairing can curb mis-hooping. Even if you use alternative holding systems or frames alongside standard hoops, this organizational habit pays dividends. And when you expand your toolkit to include specialty gear, verify your design boundaries, just as carefully as you would with standard brother hoops.