Brother PE540D Review In Detail

Brother PE540D Review In Detail

Brother PE540D is an excellent embroidery machine. The additional 35 Disney designs make it even more special. But the embroidery area is slightly small for professionals.

Editor rating

Brother PE540D is an embroidery only machine. This machine is very similar to the popular PE525 embroidery only machine. The only thing that makes Brother PE540D different, is the 35 Disney Designs it has built-in. The graphics on the machine clearly suggests what it packs. It is an adorable embroidery machine. Yes, the pre-loaded Disney designs are the main attraction, other than that, the machine is pretty much same as PE525. PE525 has 70 built-in embroidery designs, whereas PE540D has an additional 35 Disney designs, so 105 built-in embroidery designs in total. PE540D packs 5 embroidery lettering fonts. A total of 120 frame pattern combinations are available on this machine.

The embroidery area of Brother PE540D clearly suggests that it is a beginners embroidery machine. The maximum embroidery area is 4"x4" and it comes with one 4" x 4" hoop. The backlit LCD touch screen of this machine is a wonder on itself. While selecting a stitch, all the design options will be displayed. Once you select a particular design, the machine will tell you which thread color to use. The LCD display is very user-friendly, even a small kid would be able to use it. The screen brightness is also adjustable (this is not a feature that you normally get on machines in this segment). One good thing that Brother did with the display is that, they have included on-screen help tutorials, which means you don't need to search for the user manual if you need some assistance.

Even better thing about Brother PE540D is that it comes with computer connectivity, embroidery card slot and built-in memory. Basically what this means is that you will get access to over 5000 designs available at You can simply import those designs to your machine, in case you want more creativity. However, some of the designs need to be purchased. The supported design file format is .pes. Since PE540D comes with USB connectivity, you will get free machine updates as soon as the new version is available. However, the USB port available on the machine is 'Type B', which means you can't directly insert a normal USB stick into the machine. Instead it comes with a USB cable which can be connected to your computer or laptop.

The single LED bulb illuminates the workspace reasonably well. The automatic needle threader threads the needle in one touch. An automatic thread cutter is also provided. The drop-in bobbin with see through cover is very useful. The motor of Brother PE540D is capable of delivering 400 stitches/min. Layout function and pattern rotating are also available. The machine weighs around 18.078 lbs, so you can say that it is in the mid-range in terms of weight.

Ease of Use

Setting up Brother PE540D is easy, especially if you have some experience with computerized sewing machines. If you are a complete beginner, read the user manual completely before starting out. The user manual does need some improvement, but it is manageable. It could have been more diagram based in my opinion. Threading the machine is very easy. The LCD touchscreen is user-friendly and is easy to navigate. The thread color recommendation feature is absolutely wonderful. 

When you are importing designs, make sure that you select and save them, otherwise the patterns will disappear once you turn off the machine. This machine is not super heavy, but it is very solidly built. You won't feel any vibrations while this machine is in operation. All the patterns come out good. The stitch quality is excellent. The machine will beep an alarm once it is finished. There is nothing to worry about the performance of PE540D as it belongs to the family of the good old PE500, which on itself was a wonderful embroidery machine.


Professionals might not like the slightly small 4" x 4" embroidery area, as they will be dealing with larger projects on a regular basis. The embroidery area is good enough for beginners but if your objective is to do large projects, then you might need embroidery machines with bigger embroidery area, like the Brother PE770.


•    Additional Disney patterns
•    Easy to use
•    Lot of features
•    Wonderful LCD display


•    Slightly small 4" x 4" embroidery area

Review Verdict

Brother PE540D is a quality embroidery machine, no question about it. But what makes it even more appealing is the extra Disney designs you get. It will cost you a lot of money if you were to go and purchase those designs separately. 


TypeEmbroidery Only
Max Embroidery Area4" x 4"
Built-in StitchesNo Sewing Stitches
Embroidery Hoop1 hoop, 4" x 4"
Sewing Start/Stop ButtonYes
Embroidery Speed400 Stitches/min
Speed Control SliderNo
Built-in Embroidery Designs70+35 (Disney) = 105
Automatic Needle ThreaderYes
Layout FunctionYes
Buttonhole StylesNo
Pattern Rotation1, 10, or 90 Degrees
Top Drop-in BobbinYes
USB ConnectivityYes
Stitch SelectionLCD Touch Display
Embroidery Card SlotYes
Built-in MemoryYes
Programmable Needle Up/DownYes
Built-in Monogramming FontYes, 5
Adjustable Presser Foot PressureNo
Work LightYes, 1 LED
Included FeetEmbroidery Foot "Q"
Machine Weight18.078 lbs (with embroidery unit attached)
Automatic Thread CutterYes
On-screen Help TutorialsYes
CoverDust Cover

Disclaimer: The opinions expressed here are the views of the writer only. Opinions may be subjective.