PVC and rubber patches
PVC patches are moulded, not stitched. Liquid rubber is poured into a die and cured, which means the patch is waterproof, does not fray, holds a sharper edge than thread ever will, and can be built up in layers so the artwork is physically raised.
| Price | From $1.85 per piece — full grid on patch pricing |
| Minimum order | 50 pieces |
| Production | 10–12 business days standard, 5–7 rush at no extra charge |
| Shipping | Free and tracked worldwide, usually 3–7 business days in transit |
| Proof | Free digital proof — nothing is made until you approve it |
| Payment | 50% deposit once the proof is approved, 50% before dispatch |
2D or 3D
2D is flat: colours sit side by side at one height, like a moulded sticker. 3D steps the layers so the logo stands above the field — usually two or three levels. 3D reads better at a distance and costs more, because each level is another mould operation.
Where PVC beats thread
- Anything that gets wet — marine, outdoor, hiking, motorsport
- Tactical and service kit, where the patch is swapped between garments on Velcro
- Artwork with hard geometric edges that embroidery softens
- Glow-in-the-dark and reflective elements, which mould in cleanly
PVC patch sizes and common uses
PVC patches usually run between 1.5 and 4 inches. These are the sizes people order most:
| Use | Common size | Usual backing |
|---|---|---|
| Morale patch | 3 × 2 in | Velcro (hook) |
| Flag patch | 3 × 2 in | Velcro (hook) |
| Operator or tactical cap front | 3 × 2 in | Velcro (hook) |
| Name or callsign tape | 3 × 1 in or 5 × 1 in | Velcro (hook) |
| Backpack or bag | 3 – 4 in | Velcro or sew-on |
| Fashion cap front | 2.5 in | Sew-on |
Need Velcro on the gear too? See custom Velcro patches and Velcro patches for backpacks.
Specification
| Item | Standard |
|---|---|
| Material | Soft PVC / silicone rubber |
| Relief | 2D flat or 3D layered |
| Colours | Solid colour fills; no gradients |
| Edges | Die-cut to any outline, including cut-outs |
| Typical size | 1.5–4 inch |
| Minimum order | 50 pieces |
| From | $1.85 per patch |
Choosing a backing
Velcro is the usual pairing. The hook side is moulded or sewn to the patch and the loop side is sewn to the garment once, so one panel can take a whole set.
| Backing | Best on | Notes |
|---|---|---|
| Velcro (hook & loop) | Tactical, service and ID panels | Designed to come off — the loop side is sewn to the garment once |
| Sew-on (plain back) | Anything, including technical fabric | The only backing that reliably outlives the garment |
| Magnetic | Garments you cannot pierce | No holes at all; keep away from cards and devices |
How do I order PVC and rubber patches?
- 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.
What do you guarantee on every order?
These are the terms every order is made under — the same ones written in our order terms, not a sales promise.
- Free proof, usually the same working day. It shows size, thread colours, border and backing.
- Unlimited free changes. Ask for as many proof revisions as you need.
- Nothing is made until you approve it in writing. You can cancel free of charge at any point before approval.
- Remade at our cost if it does not match the proof. Tell us within 14 days of delivery with photos and we cover the remake and the return shipping on our errors.
- No setup or digitizing fees. Redrawing and digitizing your artwork is part of the price.
- Free tracked shipping worldwide.
Honest limits: thread is matched as closely as thread allows, so a small shift against a printed Pantone chip is normal, and very fine detail is flagged on the proof before you approve it.
Common questions
Can PVC patches have gradients?
No. Rubber is poured as solid colour, so a gradient has to be re-drawn as bands. If the artwork depends on shading, woven or sublimation is the better construction.
Do they survive a washing machine?
The patch does. Wash cold and air dry — heat is what damages PVC, not water, so keep them out of a hot tumble dryer.
Can you iron on a PVC patch?
No. Heat is what damages PVC, so an iron or heat press will distort the rubber before any adhesive bonds. Use a Velcro, sew-on or magnetic backing instead.
Are PVC patches better than embroidered?
For anything that gets wet, needs hard, sharp edges or glow-in-the-dark detail, yes. For a classic textured look at the lowest price, embroidered wins — it starts from $0.75 against $1.85 for PVC.
How do you sew on a PVC patch?
Stitch through the flat outer border rather than the raised artwork, using a heavy needle (a denim or leather needle) and polyester thread. Go slowly on a machine, or hand-sew with a backstitch.
Ready to order PVC patches?
Send the artwork and say whether you want it flat or layered, and we will quote both and proof the one you pick.
Get a free quote
Send us your artwork, size and quantity for PVC and rubber patches and we will come back with a price and a free digital proof. Nothing goes into production until you approve the proof, and shipping is free worldwide.
Related reading
- Custom silicone patches — the softer, thinner heat-applied alternative to PVC
- Patch types compared — PVC against embroidered, woven and leather
- How to apply a patch — including hook-and-loop panels
- What is a hook-and-loop patch — how the Velcro backing is fitted, and why the panel is stitched
- How to put a patch on a backpack — MOLLE grids and why coated nylon cannot take heat
- Army OCP patch placement — which sleeve each patch goes on
- Air Force OCP patch placement — quoted from DAFI 36-2903
- Custom Velcro patches — hook and loop on any face, not just PVC
- Custom iron-on patches — why heat-seal is not an option on coated fabrics
- Velcro patches for backpacks
- Custom morale patches
- How PVC patches are made