Free online EXP to PES converter

Brother embroidery machines and software commonly require PES, while Melco-compatible systems often provide EXP files. Converting the file allows an existing stitch design to be loaded into PES-based equipment or opened in software that does not support EXP.

What the EXP format is

In machine embroidery, EXP usually means the Melco expanded embroidery format. It stores machine-level commands such as needle movements, jumps, and stops rather than the editable objects, outlines, fills, and lettering found in a native digitizing file.

EXP files are used in Melco-compatible production systems and older embroidery design libraries. They are primarily stitch files, so thread colors and other design metadata may be missing or incomplete. The file may therefore require manual color assignment after import.

What the PES format is

PES is the embroidery format associated with Brother and compatible machines. It stores stitch data, color-change blocks, design dimensions, and thread-color information when that information is supplied by the exporting software. Some PES versions and software workflows can also retain additional design information, but converting an EXP stitch file does not recreate editable objects that were absent from the source.

PES is the appropriate output when a Brother machine or application specifically requires a .pes file. Compatibility still depends on the machine's supported PES version, hoop size, and stitch limits.

How to convert EXP to PES

Convert on 101convert.com

1. Open the EXP-to-PES converter on 101convert.com. The conversion is available free without installing software.
2. Upload the machine-embroidery file with the .exp extension.
3. Select PES as the output format and start the conversion.
4. Download the resulting .pes file and open it in embroidery software to check its dimensions, stitch count, color blocks, and thread assignments.

Uploading is unsuitable for confidential or restricted designs; use desktop software for those files.

Convert with desktop embroidery software

Wilcom TrueSizer, Embird, Hatch Embroidery, and Ink/Stitch can import or open many EXP files and export PES, although supported versions and menu names differ.

1. Open the .exp file with File → Open or the program's import command.
2. Inspect the stitch preview and assign thread colors to each color block. Do not assume the displayed palette represents colors stored in the EXP file.
3. Check the design's actual dimensions against the Brother machine's hoop. Resize it if necessary rather than relying only on a different hoop selection.
4. Use File → Save As or File → Export, choose PES, and select the PES version supported by the target machine when the program provides that option.
5. Reopen the exported file and inspect color changes, jumps, trims, stops, stitch count, and placement before transferring it to the machine.

Quality and compatibility limitations

Conversion changes the file format and may add metadata; it does not improve the underlying digitizing. An EXP file generally cannot provide the original lettering, appliqué settings, fill types, stitch angles, object boundaries, or other editable design data. If the original native design file exists, export that file directly to PES instead.

Because EXP color information may be absent, the converted PES can contain correct stitch blocks but incorrect or generic thread colors. Verify the needle-change sequence and assign the intended thread chart before sewing.

Simulate the PES file and sew a test sample when possible. Check the design's hoop fit, maximum stitch length, jump and trim behavior, needle changes, and the PES version accepted by the specific Brother machine. Keep the original EXP file unchanged so the conversion can be repeated with different colors or machine settings.