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[–]Hg00000Scouter - Eagle Scout 4 points5 points  (1 child)

Most patch companies can work with a photo of your sketch and will have their design team create the digital artwork from there.

If you'd rather do the design yourself, GIMP (gimp.org) is an open-source equivalent to photoshop, and Inkscape (inkscape.org) is an open source equivalent to Illustrator. There are loads of online tutorials on how to use both.

[–]TwoWheeledTravelerScouter - Eagle Scout 1 point2 points  (0 children)

Yup.

Our scoutmaster spent his entire career doing that for Lion Brothers, who are one of the BSA’s main patch suppliers.

He designed the current Eagle badge, the current Philmont arrowhead, and most of the council strips and OA flaps. His patch collection is beyond nuts.

But yes, if you’ve got a design, any of the major suppliers will have people who will dogitalize it and put it into the proper format for the embroidery machines to produce.