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I do embroidery amoungst other things and did look into this (embroidery on to race suits), actually as I recollect you should be OK with patches but not with embroidering directly on the race suits (presuming that is what you want to do) even with nomex thread. You can get patches that heat press on and that may be a better option as you do not need to punture the suit. Though be prepared to pay a bit to set up the file (digitise), I do have some very powerful software called Corel DRAWings (Not Corel Draw but from the same people) where I can convert an illy file into an embroidery file, if you want to email it to me I will at least have a look at it and see what is envolved and if the file is doable.
PS mods I am not touting for work as I am more into embroidering direct on to garments and selling the garments than patches.
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