WHY_CONVERT: EXP → PES
EXP is the native format for Melco and Bernina embroidery machines, widely used in commercial digitizing studios and professional embroidery shops. But if you own a Brother or Baby Lock home machine, EXP files won't open directly. Your machine needs PES.
ThreadShifter converts EXP to PES in under a second. No software, no account, no limits. Upload your Melco EXP file, download a PES file that works on every Brother machine from the PE800 to the Luminaire XP1.
PROCEDURE // 3_STEPS
1. UPLOAD YOUR EXP FILE
Drag and drop your Melco EXP file onto the converter, or click to browse. Files up to 50MB accepted. The converter works with any EXP file — Melco Amaya designs, Bernina Deco files, or any EXP-format embroidery.
TROUBLESHOOTING: If upload fails, check that the file extension is .exp and the file isn't corrupted. Some older Bernina software exports EXP with embedded metadata that can cause issues — try re-exporting without metadata.
2. SELECT PES AS TARGET
Choose "PES (Brother)" from the format selector. Optionally select your hoop size (4×4, 5×7, 6×10, or custom) and ThreadShifter will auto-scale the design to fit.
PRO TIP: Know your machine's hoop size before converting. Brother PE models typically use 5×7, while SE models often use 4×4.
3. DOWNLOAD & EMBROIDER
Click "Convert & Download". Your PES file is ready instantly. Transfer it to your Brother machine via USB or wireless connection, and start embroidering.
TROUBLESHOOTING: If the design doesn't appear on your machine, try re-formatting your USB drive as FAT32. Brother machines may not read exFAT or NTFS drives.
WHAT PES GIVES YOU THAT EXP DOESN'T
| Feature | EXP | PES |
|---|---|---|
| Thread Color Info | ||
| Design Preview / Thumbnail | ||
| Hoop Size Metadata | ||
| Machine-Specific Settings | ||
| Home Machine Compatibility | ||
| Universal File Access | ||
| BEST FOR | Melco & Bernina Studios | Brother & Baby Lock |
REAL_USER_SCENARIOS
SCENARIO 1: Digitizer Sending to a Brother Customer
"I run a digitizing service and work on a Melco Amaya. Most of my home-embroiderer clients use Brother machines. Instead of buying separate software to export PES, I send them their EXP files with a link to ThreadShifter. They convert it themselves in seconds."
✓ THREADSHIFTER SOLVES THIS
SCENARIO 2: Bernina User Switching to Brother
"I upgraded from a Bernina Deco 650 to a Brother Luminaire XP1. All my design library is in EXP format. ThreadShifter converted my entire collection to PES in minutes. I didn't lose a single design."
✓ THREADSHIFTER SOLVES THIS
SCENARIO 3: Commercial Shop Expanding to Home Sales
"Our shop uses Melco machines and sells embroidery designs online. Many customers use Brother machines and can't open EXP files. Now we offer PES versions alongside our EXP files — generated instantly with ThreadShifter. No extra software, no overhead."
✓ THREADSHIFTER SOLVES THIS
COMMON_USE_CASES
- • Converting Melco Amaya EXP designs for Brother home machines
- • Adapting Bernina Deco EXP files for Brother PE/SE series
- • Sharing professional digitized designs with Brother-using clients
- • Switching from a commercial Melco setup to a home Brother machine
- • Converting EXP design libraries when upgrading between machine brands
- • Preparing EXP files from embroidery studios for home embroidery use
UNDERSTANDING_THE_FORMATS
EXP (Melco) — PROFESSIONAL DIGITIZING FORMAT
EXP is the native format for Melco embroidery machines, also used by Bernina. It stores stitch data, thread color information, and machine-specific settings. EXP files are commonly created by professional digitizing software like Wilcom, Pulse, and Embird. Melco machines (Amaya, Bravo, EMT series) read EXP natively, and the format supports up to 16 needle positions with color change sequencing.
FILE EXTENSION: .exp • USED BY: Melco, Bernina
PES (Brother) — HOME EMBROIDERY STANDARD
PES is Brother's native format, used by every Brother and Baby Lock home embroidery machine. PES files contain everything your Brother machine needs: stitch data, thread color assignments, a built-in design preview image, hoop size information, and Brother-specific settings. PES v6 (the version ThreadShifter outputs) is compatible with all modern Brother machines.
FILE EXTENSION: .pes • USED BY: Brother PE/SE/Innovis, Baby Lock
COMPATIBLE_BROTHER_MACHINES
ThreadShifter outputs PES v6, compatible with every Brother and Baby Lock machine. Here are the most common models and their hoop sizes:
NOTE: Brother machines with 4×4 hoops (SE600, Innovis 4000D) may crop designs larger than 100×100mm. Use the hoop selector in ThreadShifter to auto-scale.
TROUBLESHOOTING_GUIDE
EXP FILE WON'T UPLOAD
Check that your file has the .exp extension. Some digitizing software exports EXP files with embedded thumbnails that can confuse file parsers. Try opening the EXP in your original software and re-exporting as a clean EXP without preview data.
COLORS LOOK DIFFERENT AFTER CONVERSION
EXP files store thread color information using Melco's color palette, which maps differently to Brother's PES palette. The stitch data itself is preserved perfectly — you can reassign colors on your Brother machine. Open the design and use the color palette to match your threads.
DESIGN WON'T FIT YOUR BROTHER HOOP
Your EXP file may have been created for a larger commercial hoop (Melco machines can handle up to 14×14). Before converting, select your machine's hoop size in ThreadShifter's dropdown. The converter auto-scales to fit.
STITCH COUNT EXCEEDS MACHINE LIMIT
Melco commercial machines can handle very high stitch counts. Brother home machines typically support up to ~50,000 stitches per design. If your EXP file has more, consider splitting the design into multiple PES files or reducing stitch density in digitizing software before converting.
FILE WON'T OPEN ON MY BROTHER MACHINE
Try re-downloading the converted file. Check your USB drive format: Brother machines require FAT32. If the design still fails, the original EXP may contain unsupported stitch types (like extended jumps or specialty stitches that Melco supports but Brother doesn't).
WHAT_YOU_GET_WITH_THREADSHIFTER
- Instant Conversion: EXP to PES in under 2 milliseconds
- Smart Color Mapping: Color data from EXP preserved in PES
- Universal PES Compatibility: Outputs PES v6 (works on all Brother machines)
- Hoop Safety: Auto-scales to 4×4, 5×7, 6×10, or custom sizes
- 8 Format Support: DST, PES, JEF, EXP, XXX, VP3, U01, PEC
- Privacy Protected: Files never stored, zero data retention
- Unlimited Conversions: No limits, no restrictions, forever free