Choosing a patch type

Thread stitched onto a twill base. This is the classic patch with visible texture and a raised feel. It suits bold shapes, solid lettering and designs with a limited number of colors. Coverage can be partial (twill showing as a background color) or 100% embroidered.

Limits: text below roughly 6 mm high and very thin lines lose definition. If your logo relies on fine detail, consider woven or printed instead, or let us simplify the artwork on the proof.

Made by weaving fine threads rather than stitching on top of a base. The surface is flat and smooth, and detail is much finer than embroidery, so small text, thin outlines and intricate crests reproduce well.

Woven patches feel less textured than embroidered ones. Choose woven for detailed logos, name labels and slim designs.

Moulded soft PVC in layers. Colors are solid and bright, edges are crisp, and the patch is waterproof and hard-wearing. PVC suits outdoor gear, bags, tactical use and any design with flat color areas. 2D PVC is flat with layered colors; 3D PVC adds sculpted height.

Limits: PVC cannot reproduce gradients or photographic detail, and it is usually paired with a hook-and-loop backing rather than sewn directly.

Loops of yarn give the fuzzy, raised varsity-jacket look. Chenille works for large letters, numbers and simple shapes, often with an embroidered or felt border. It does not hold small detail and is best at sizes from around 75 mm upward.

Printed (dye-sublimated) patches reproduce photographs, gradients and very fine detail on a fabric base, usually finished with an embroidered border. They are the answer when the artwork simply cannot be stitched.

Leather patches are debossed or laser-marked genuine or faux leather, common on caps, denim and premium apparel where a single-tone mark is wanted.

Backing determines how the patch attaches: iron-on (heat-seal) for pressing onto cotton and polycotton, sew-on for permanent attachment or stretch fabrics, hook-and-loop for removable use, and adhesive for short-term use.

Borders: a merrowed edge wraps the perimeter with thread and suits regular shapes such as circles, shields and rectangles. A hot-cut or laser-cut edge follows custom shapes cleanly.

Size is measured across the longest dimension. Keep at least 2–3 mm between important detail and the border so nothing is lost in the edge finish.

• Bold logo, classic look: embroidered
• Small text or intricate crest: woven
• Outdoor, bags, gear: PVC with hook-and-loop
• Varsity letters: chenille
• Photo or gradient artwork: printed
• Single-tone premium mark on caps or denim: leather