Patch types
Here is how PVC patches are made. A PVC patch is not stitched at all. It is poured: coloured liquid PVC is filled into a mould one colour at a time, then heat-cured into a flexible, rubbery patch. That process is why PVC patches have crisp edges, raised 3D detail and survive rain, mud and scrubbing.
Short answer. PVC patches are made by cutting a custom mould from the artwork, filling it with liquid PVC one colour at a time, curing it with heat so the PVC sets into a solid flexible piece, then removing it from the mould and fitting the backing. Each colour is a separate fill, and raised detail comes from depth cut into the mould.
How PVC patches are made, step by step
- Artwork is converted to a mould design. Each colour becomes a separate area, and raised levels are marked for depth. Lines need to be thick enough to fill — very fine hairlines do not mould cleanly.
- A custom mould is cut. The mould is engraved or machined with the design in reverse, including the different depths for 2D and 3D areas. One mould is made per design, which is why PVC pricing includes mould set-up.
- Liquid PVC is coloured. PVC is mixed with pigment to match each colour in the design.
- Colours are filled one at a time. Each colour is dispensed into its own area of the mould, usually starting with the smallest details, and partly set before the next colour goes in so they do not bleed.
- The backing layer is poured. A final layer fills the whole shape and forms the base that holds all the colours together.
- The patch is heat-cured. The mould goes into an oven, where heat turns the liquid PVC into a solid, flexible material.
- It is cooled and removed from the mould, trimmed, and inspected.
- The backing is fitted — sew-on, Velcro hook, heat-seal or adhesive — or hardware is added for keychains.
2D vs 3D PVC patches
| 2D PVC | 3D PVC | |
|---|---|---|
| Levels | Flat layers at one or two heights | Sculpted, rounded detail at several heights |
| Look | Clean and graphic | Dimensional, like a small moulded badge |
| Best for | Logos, text, flat artwork | Mascots, faces, emblems with depth |
Why PVC patches are priced differently
Because every design needs its own mould, PVC has a fixed set-up cost that embroidery does not, and 3D relief adds work to the mould. That is why PVC starts at $1.85 a patch against $0.75 for embroidered. Once the mould exists, every patch comes out identical. See the PVC patches page for options and the price list for the grid.
Common questions
Are PVC patches made of rubber?
They are made of PVC, a soft plastic that feels rubbery once cured. That is why they are often called rubber patches.
Can you make PVC patches at home with liquid PVC?
Hobby kits exist, but they need a mould, pigments, and an oven or heat gun to cure the PVC, and results are hard to control. For more than a few patches, a made-to-order run is cheaper and more consistent.
How long do PVC patches last?
Years. PVC does not fray, fade quickly or absorb water, which is why it is the standard for outdoor and tactical gear.
What is the minimum order for PVC patches?
50 pieces per design, the same as all our patches.
Have these made
More in this section: patch types compared — every construction side by side.
Need patches made?
We make embroidered, chenille, woven, leather and PVC patches to order — from $0.75 a patch, with a free digital proof before production and any backing you need.