It is my opinion that they were done by hand without the use of a template...early on. I agree that there are many variations... even on tunics. I tend to think that tas the LW grew, they could have been done by a type of machine as mentioned above. The quickest way I can see these being made is to have a sheet of the waffenfarbe material and have many of the rank insignia embroidered onto that sheet. Next, each individual insignia would be cut off in measured blocks. Next, a light adhesive would be applied to the reverse of the insignia. Finally, the embroidered cloth would be wrapped around the backing material where the edges would be folded and secured to the back. Could you imagine the job satisfaction involved in making these all day long... every day?!!? I would go crazy! In this case, my definition of hand sewn was; "sewn by a machine that was run by an individual". I could not imagine these being done literally by hand...