My daughter needed a few personalized gifts for her nurse co-workers so I ordered a few blank badge holders and embarked on my first badge holders. I chose a Curly font for the initial and then used small squares of fabric. I chose thread that would contrast with the fabric and set to work.
First of all I embroidered an initial on the fabric using the 4x4 hoop; initial is .76 x .78 inches. As you can see below I was able to do several in one hooping.
I then removed the hoop and proceed to cut out the initial by placing the clear plastic circle on the fabric and just cutting around it. I took the cutout initial and trimmed it to fit perfectly inside the indentation of the badge holder.
Next I popped on the clear cover and the badge holder was done. Because I am never certain that the cover will stay on indefinitely, I put a few dabs of super glue around the edge before putting the cover on.