The patch looks embroidered to me. I think the reason the inside looks flatter is because the outside is edged, which is a thicker stitch.
I think you're right! I think the whole interior is a very low profile embroidery. Now, the other thing I'm trying to figure out is whether the endurance ship has a thin grey stroke on the patch just like the concept art from the book. Some of the screen shots seem to show a border, but it could be an illusion:
I also spoke to my embroidery company and if we go ahead and run the patch EXACTLY as in the above concept art from the book (with the grey border surrounding the ship) with all the little irregularities and imperfections, it will look good but they say we may miss some of the fine details...and that it may end up looking like these screen shots from the film suit!!! Which is funny because that's exactly what we want
I've created an identical replica of the above concept art in vector format. I also made sure to make the "Space Exploration" text larger, centered and exactly like the movie patch you see.
The only things remaining now are to choose colour of the patch and thread, what should be embroidered and at what height, the direction of stitching for each element, whether the ship has a thin grey and irregular border and size.
I vote for the following:
1) the thick grey border of the patch should be embroidered higher than any of the interior embroidery
2) the ship should have a thin grey border exactly as in the concept from the book
3) rather than having a perfect shape for each part of the ship, I personally think they used a version of the concept you see above and embroidered the patch with the interesting irregularities of the ship. (ie: each ship rectangle has bumps and edges that aren't perfect)
4) The height of the patch should be 4" from bottom tip to the top of the patch
5) I have selected this colour as the blue for the patch:
6) Obviously the film has colour grading so the thread can't be matched exactly. I personally think the main "white" thread from the patch is white, or slightly off white, and the grey thread is something like this:
Any more thoughts would be appreciated
-Bartek
PS: If anyone is wondering, I used to be on this forum YEARS ago under a different alias ("Bobo") but my account expired so I now have this one. I made plenty of transactions making circuitry for Boba Fett rangefinders both on here and TDH.
http://www.thedentedhelmet.com/members/bobo/
http://www.thedentedhelmet.com/f23/rf-led-kits-thanks-3338/