Hi Linda, My embroidery machine has shapes built in to it. There are many with different shapes. Are you sure your machine does not have these? H&*
Go to www.emblibrary.com then go to projects, they have instructions for all sorts of things. Even have a video to see how its done. Margaret
The size of your patch is something only you can decide as you know the size of the design to put in it.
I uploaded several patches (I added links to two of them) in Designs by Cuties, and I'm not the only one. At the moment there are a number of patches by zazmau with a grid or other filling you can easily leave out if you wish.
If you use it as an applique on a shirt I'd use a cotton of the same weight.
Hoop the shirt with a tear or cut away stabiliser, stitch the first outline (the placement line, put your patch fabric on top, stitch the second line and cut the fabric back to the outline, then embroider your design.
Or if you wish you could to it in two hoopings. First you hoop stabiliser and embroider your motive. Then remove the stabiliser from the back and hoop your shirt and continue as described above.
Thank you, thank you, thank you! You told me everything I should need to know about making a patch...I really appreciate your time...Linda
Glad you got it, as I made a mistake in the last paragraph. It should read:
first hoop your stabiliser AND YOUR PATCH FABRIC and embroider your motive.