Custom embroidered patches
Embroidered is the default for a reason: thread on twill is durable, it reads well at arm’s length, and it is the cheapest construction per unit once you are past a hundred pieces. It is also the construction with the hardest limit on fine detail, which is the single thing most first orders get wrong.
How an embroidered patch is built
A polyester twill backing is hooped, and a digitized stitch file drives the needle. Coverage is what you are paying for: a design that leaves twill showing between elements is roughly 50% coverage and sits at the standard rate; one where thread covers the whole face is 100% coverage and carries a 15% uplift, because it is nearly twice the stitches.
The edge is finished separately. A merrowed border wraps a raised cord around the cut edge and suits circles, ovals and soft-cornered shapes. A laser or hot-cut edge follows complex outlines but needs enough body to survive handling. If you have not specified an edge, the supplier picks one — usually whatever the machine is already threaded for.
What it does well, and where it stops
| Works | Struggles |
|---|---|
| Bold logos, lettering above about 5 mm cap height, flat colour blocks | Photographic gradients, thin serifs, drop shadows |
| Left chest, cap front, sleeve, full back | Anything under 1.5 in that carries text |
| High-wash garments — uniforms, workwear, scouting | Fine linework that thins below one stitch column |
Specification
| Item | Standard |
|---|---|
| Base cloth | Polyester twill; felt and canvas on request |
| Thread colours | Nine included; custom Pantone matching available |
| Coverage | Up to 50% included; add 15% for full coverage or specialty thread |
| Edges | Merrowed, hot cut, laser cut |
| Minimum order | 50 pieces |
| Lead time | 10–12 business days standard, 5–7 rush at no extra charge |
Embroidered patch pricing
Per patch, including digitizing, up to nine thread colours, twill backing and a merrowed border. Quantities above 1,000 and sizes above 4.5 inch are quoted individually, up to 10,000 units.
| Size | 50 pcs | 100 pcs | 300 pcs | 500 pcs | 1000 pcs |
|---|---|---|---|---|---|
| 2 inch | $2.95 | $1.85 | $1.10 | $0.95 | $0.75 |
| 2.5 inch | $3.45 | $2.15 | $1.35 | $1.15 | $0.90 |
| 3 inch | $3.95 | $2.55 | $1.60 | $1.35 | $1.05 |
| 3.5 inch | $4.65 | $2.95 | $1.90 | $1.60 | $1.25 |
| 4 inch | $5.35 | $3.45 | $2.25 | $1.90 | $1.55 |
| 4.5 inch | $6.15 | $3.95 | $2.65 | $2.25 | $1.85 |
Choosing a backing
| Backing | Best on | Notes |
|---|---|---|
| Iron-on (heat seal) | Cotton and cotton-rich blends | Permanent enough for everyday wear; will lift on nylon, waterproofs and heavy fleece |
| Sew-on (plain back) | Anything, including technical fabric | The only backing that reliably outlives the garment |
| Velcro (hook & loop) | Tactical, service and ID panels | Designed to come off — the loop side is sewn to the garment once |
| Peel-n-stick | Events, samples, photography | Temporary. Not a wash-safe backing |
| Magnetic | Garments you cannot pierce | No holes at all; keep away from cards and devices |
| Button loop | Caps, bags, lanyards | Hangs rather than attaches |
How ordering works
- Send artwork. Any format — a logo file, a photo of an old patch, or a sketch on paper.
- Approve the proof. You get a digital proof with the size, colours and border marked. Nothing runs until you sign it off.
- Production. 10–12 business days as standard, 5–7 on a rush, at no extra charge.
- Tracked delivery. Shipped worldwide, to you or straight to your printer.
Common questions
What size should I order?
Left chest sits between 3 and 3.5 inches on adult garments; a cap front is limited by the crown, usually 2.25 inches tall. The placement guide gives measured positions and size ranges for every common garment.
Can you match my brand colours exactly?
Close, yes — thread is dyed in fixed shades, so a Pantone match is the nearest available thread rather than an exact ink match. Send the Pantone reference and the proof will show what it will actually look like.
Do I own the digitized file?
Yes. The stitch file is produced for your artwork and is yours to take elsewhere.
Ready to order embroidered patches?
Send the artwork, a size and a rough quantity. You get a price and a free digital proof back — usually the same working day.
Related reading
- Patch types compared — how embroidery stacks up against woven, chenille, leather and PVC
- Borders and edge types — which edge your shape can actually take
- Thread, twill and materials — what the patch is made from, and how it behaves in a wash