Not even close. I'm about a grand in the hole because I keep underestimating the cost of doing something. I'm losing between 50 cents and 3 bucks every time I embroider something. I should probably raise the prices by a buck or something.
Someone asked me a little while ago to make a die cut/shaped patch instead of putting the embroidery on something. I was sure it would not be possible without specialized equipment, so I didn't bother to even try.
Well, I tried recently just for sh!ts and giggles. I can't believe how well these came out, on the first try. I made some big changes to the way the thread was put down so that the design would be locked together. Without fabric in the middle, there wouldn't be much directional stability to the design unless the embroidery thread was doing the stabilizing. I also used several different types of non-directional stabilizer, and a lot more of it than a normal design.
I tried pulling one apart, and I was unable to do it by hand. I put one end in a vice, and tried pulling it apart in the strongest direction (left to right in this pic), and was unable to do it, even with my press. Thinking about it later, this makes sense. The thread I am using is pretty close to the thread used in tow straps, so the strength for a given size should be roughly equivalent. Theoreticly, I can weave a tow strap on my embroidery machine 4 inches at a time as long as I have the thread running the right way.
I think it would be possible to turn every design I have done into a patch, though some would be significantly harder than others to convert. The best part is that these three only cost me $1.83 in materials each. Doing a full size design would equate to about $5.40 in materials, about 40 cents more than putting the design on a short or something. When I priced out custom patches like this for another project about a year ago, I couldn't find anything cheaper than $14, and that needed several thousand count minimum in order to defray the giant setup cost. It's bonkers to me that I can make them almost an order of magnitude cheaper, and with a minimum of 1 instead of a few thousand.