Custom Patches

Every type.
Every detail.

Four construction methods, seven backing options, sizes from 1.5 inches to a full jacket back. Everything spelled out so you can order knowing exactly what you are getting.

Brightly colored custom embroidered patches showing detailed thread stitching and clean borders

Construction 01

Embroidered patches

Embroidered is the original and still the most ordered. Thread (polyester or rayon) is stitched onto a twill or felt backing fabric in a pattern generated from your artwork. The resulting patch is tactile, colorfast and extremely durable.

Thread coverage determines the look. Fifty percent coverage leaves background fabric visible and costs less; 75% is the most common choice for club and band patches; 100% coverage is full-surface thread (no fabric showing at all) which suits highly detailed logos and photographic imagery.

Borders are either merrow (a wrapped, rounded edge. The classic biker patch look) or heat-cut (laser-trimmed to a precise shape — better for complex outlines, skulls, animals, custom shapes). Standard shapes are round, oval, rectangle and shield. Custom die-cut shapes are available on orders of 100 pieces or more.

Spec	Detail
Minimum size	1.5 in × 1.5 in
Maximum size	14 in × 10 in (back panel)
Thread colors	Up to 15 colors (most designs use 4–8)
Coverage options	50%, 75%, 100%
Border options	Merrow, heat-cut, laser-cut custom shape
Minimum order	50 pieces
Sample single piece	Available — contact us

Construction 02

Woven patches

Woven patches are flat — thread fills the entire surface with no raised texture, stitched on a loom rather than embroidered over backing. That flatness is the point: the weave holds details that embroidery simply cannot — thin serif fonts, thin lines, gradient shading, small print down to 4pt text.

If your logo has tiny type that would turn to mush in embroidery, woven is the answer. Bands use woven patches for back-of-collar labels. Brands use them for woven labels on hats and bags. They are also popular for thin-line heraldic designs where the traditional embroidered look would lose all the fine elements.

No background fabric is visible; the weave is tight and the surface is smooth to the touch. Heat-cut edges are standard; merrow edges are available on rectangular and oval shapes only.

Spec	Detail
Minimum size	1 in × 0.5 in (label size)
Maximum size	6 in × 6 in
Thread colors	Up to 10 colors
Minimum order	100 pieces
Best for	Fine fonts, small logos, woven labels, detailed heraldic artwork

PVC rubber morale patches with bold raised 3D design elements

Construction 03

PVC / Rubber patches

Soft PVC patches are molded, not stitched. Your artwork becomes a two- or three-layer mold with raised and recessed areas that create real 3D depth. The result is waterproof, UV-stable and functionally indestructible — they go through washing machines, live on tactical gear and outdoor equipment without complaint.

These are the dominant choice for morale patches. The pop-culture, satirical and unit-insignia patches that attach to military gear, range bags, helmets and plate carriers via loop velcro. They also work brilliantly on motorcycle jackets and bags where a fabric patch would wear down at the edges.

Colors are mixed into the PVC compound rather than printed, so they are fade-resistant across years of UV exposure. Edges are precision die-cut to your shape with no fraying concern. Velcro backing comes standard on most morale patch orders; sew-on available on all shapes.

Spec	Detail
Minimum size	1.5 in × 1.5 in
Maximum size	6 in × 6 in
Colors	Unlimited (compounded into PVC layers)
3D layers	Up to 4 layers of depth
Minimum order	50 pieces
Best for	Morale patches, outdoor/tactical, waterproof applications

Chenille letter patches on a varsity jacket in school colors

Construction 04

Chenille patches

Chenille is the letterman patch material — deep, looped pile fiber that gives a fuzzy, three-dimensional texture unlike anything else. Classic chenille uses a wool felt base with a raised chenille yarn design on top; the outline is typically done in a flat embroidery border to define the shape cleanly.

Schools and sports programs are the obvious customers, but plenty of streetwear brands have brought chenille back hard in recent years. A chest-size chenille logo on a bomber jacket has a presence no flat embroidered patch can replicate. Same goes for band merchandise — a chenille patch on a tour hoodie hits differently.

Chenille is best for bold, simple shapes: block letters, numbers, shields, animals, geometric logos. Fine detail does not translate into pile fiber — if your design has thin lines or small text, pair it with an embroidered or woven element on the same patch (we can combine methods on a single piece for an extra-charge).

Spec	Detail
Minimum size	3 in (letters/numbers minimum)
Maximum size	12 in × 12 in
Colors	2–4 chenille colors standard; combo patches available
Minimum order	25 pieces
Best for	Varsity/letterman, streetwear, band merch, bold logo patches

Backing options

How your patch attaches

Every patch type above is available with any of these backing choices. Some are more common with certain constructions. We flag that below.

Backing	How it works	Best for
Iron-on	Heat-activated adhesive layer on the back. Press with an iron for 30–40 seconds. Bonds permanently to cotton, denim and wool. Not recommended for polyester or waterproof shells.	Embroidered, woven, chenille on cotton/denim garments
Sew-on	No backing layer — raw fabric back for stitching directly to the garment. Most durable long-term option. Standard for MC rocker sets and heavyweight jacket patches.	All patch types; preferred for back patches and anything structural
Velcro (hook side)	Hook side of velcro attached to patch back. Pairs with loop panels pre-sewn onto gear, bags, helmets or uniforms. Swap patches without any tools or thread.	Morale/PVC patches, military and tactical gear, interchangeable setups
Adhesive / self-stick	Peel-and-stick adhesive — good for temporary placement and hard surfaces. Not a permanent textile bond.	Display, promotional, event giveaways, sticker-style placement

Combo backing: Iron-on + sew-on is the most popular combination for embroidered patches — iron it first to hold position, then stitch the perimeter for a permanent bond. Just ask and we will add both to your order at no extra charge.

Know what you need?

Send your artwork and tell us the patch type, size, quantity and backing you have in mind. We will build a free digital proof within two business days and quote before you commit.

See the ordering process Email us now