Patch types
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.
Do you sew the hook side or the loop side?
The loop side, onto the garment. The hook side belongs on the back of the patch, and on a made-to-order Velcro patch it is already fitted.
Can I glue or iron the loop panel on instead?
Not if the patch will be taken off and put back. Every pull puts the whole force into the panel, and adhesive gives way at a corner after a few washes. Stitch it through all four sides.
What thread is best for sewing on Velcro?
Strong polyester thread in the colour of the garment. It will not rot or shrink like cotton, and matching the garment rather than the panel hides the stitch line when no patch is fitted.
Can I sew Velcro onto a backpack or plate carrier?
Yes, and those are the places where it matters most. Use a heavy needle, go slowly through the webbing and add a second line of stitching or an X. If the bag has a lining you cannot get behind, see putting a patch on a backpack.
Is hand sewing strong enough?
Yes. A backstitch 2 mm from the edge all round is as strong as a machine line for normal use. Machine stitching is faster, not stronger.
Have these made
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.