Here's a sample stitchout of some embroidery I did for a comrade's Sniper Wolf Metal Gear Solid costume using Brother PE-Design 6.1 (with help with the vector EPS import plugin). It'll also be reused for several Fox Hound Genome Soldier uniforms.

It's 3.5" x 3.3" in size, 20,541 stitches (170' total bobbin), and 10 colors (9 changes). If anyone ever needs the digital tape in any format (Tajima DST, Janome JEF, EMB, Compucon XXX, Husqvarna Viking HUS, etc.) to use, email me.

--- UPDATE ---

Since I recieved the usual "anonymous" cosplay.com hatemail calling my work B.S., as expected, I recorded the actual design...

http://www.fox-hound.us/misc/FoxHound001e-Embroidery.avi

Checkmate.