EXP Converter

EXP (Melco) is a machine embroidery file format developed by Melco, a company founded in 1972 that pioneered the commercial embroidery industry. The format stores stitch data as a series of relative coordinate movements using a compact binary structure, with each record encoding the needle's horizontal and vertical displacement along with control flags for stitch type, color changes, and machine stops. EXP files use a straightforward sequential layout — stitch records follow one after another without complex headers or nested structures, making the format reliable and fast to process on embroidery machine controllers. Melco developed the format for their commercial multi-head embroidery machines, widely deployed in contract embroidery shops, uniform manufacturers, and promotional product companies. One advantage is efficiency for commercial production — the lean binary structure minimizes file size and loading time, important when operators run hundreds of designs daily on multi-head machines. The format's association with Melco's professional-grade equipment gives it credibility in the commercial embroidery sector, where reliability and speed are prioritized. Most professional digitizing software — including Wilcom, Pulse, and Hatch — supports EXP export, ensuring designs from any major platform can target Melco equipment. While EXP lacks embedded thread color metadata, its simplicity and industry acceptance have sustained its use across decades of commercial embroidery production.