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Free Digitizing Over $150 | (631) 458-3842

Custom Patches - Every Type, Every Backing, No Minimums

Embroidered, woven, PVC, leather, chenille, sublimated. Sew-on, iron-on, velcro, adhesive, button loop, magnetic. Built in-house in Huntington, NY. No minimums. Live preview before you order.

What Are Custom Patches?

A custom patch is a decorative or identifying emblem manufactured separately from a garment and attached after the fact. Patches let you brand, identify, or decorate any surface a sewing machine or hot press can reach - and unlike direct embroidery, they can be moved, swapped, replaced, or saved as keepsakes.

Patches date back to military heraldry in the 1800s and exploded in the United States after World War II, when units brought home their unit insignia and civilians adopted them for scouts, varsity letters, biker clubs, and trade unions. By the 1970s embroidered patches were the dominant form of personal expression on jackets and uniforms across the country.

They are back in a big way. Tactical morale culture, vintage workwear, leather hat patches on premium caps, custom streetwear, and the resurgence of varsity jackets have all driven a patch renaissance. Today patches are how fire departments identify shifts, how breweries decorate caps, how scouts mark rank, and how units sign their gear. They are also one of the few decoration methods that can be produced in tiny runs without exotic minimums.

EmbroideryLI builds every common patch type in-house. We carry no minimum and we offer live preview - you see your design rendered before you commit. The pages below break down every material, backing, border, and use case so you can match the right patch to the right job.

Patches solve problems that direct decoration cannot. They can be removed and saved when a uniform is replaced. They can be swapped on velcro for plainclothes, off-duty, or specialty assignments. They allow a single garment to carry agency, unit, and personal identifiers stacked together. They handle complex art that a single-pass embroidery run on a shirt would not. And because they are produced as their own object first and applied second, the production quality is higher than direct embroidery on most garments.

The result is that nearly every uniform program, team program, brand program, and tactical loadout in the United States runs on patches in one form or another. Choosing the right patch is choosing the right material, the right border, the right backing, and the right size for the application. Every page in this cluster targets one of those decisions.

Backing Options

Six attachment methods. Pick by application surface and whether the patch needs to come off.

BackingBest ForAdd-On Cost
Sew-OnPermanent attachment, no adhesive. Standard for uniforms.Included
Iron-OnHeat-activated adhesive. Cotton, polyester, fleece. Not for nylon or waterproof shells.+$2
Velcro (Hook & Loop)Removable. Standard for tactical, morale, and uniforms with patch panels.+$3
Adhesive (Peel & Stick)Temporary, single-use. Trade shows, events, samples.+$2
Button LoopMilitary and scout-style hanging tab. Pinned through a buttonhole.+$2
MagneticNametags and reusable corporate badges. No fabric damage.+$4

Border Styles

Three ways to finish a patch edge. Pick by shape complexity.

Merrowed

Overlocked thread border, raised edge. Standard for round, square, oval, and shield shapes.

Hot-Cut

Heat-sealed flush edge. Used for irregular shapes a merrow machine cannot follow.

Laser-Cut

Precision-cut to any shape, including sharp inner corners. The cleanest finish for complex outlines.

Sizing & Pricing

Embroidered patch base pricing. PVC, leather, chenille, and sublimated quoted per project.

Size
Typical Use
Price (Sew-On)
2"
Hat side, small chest, name patch
$12
3"
Standard chest, sleeve
$14
3.5"
Standard shoulder, jacket back panel
$16
4"
Large shoulder, club emblem
$18
5"
Full chest, biker back center
$22

Add $2 for iron-on, $3 for velcro. Sizes up to 12" available. Bulk pricing on orders of 25+.

Our Patch Process

From artwork to packed order, every step happens in our Huntington shop.

1. Design

Send artwork or sketch. Our team cleans up files and confirms sizing.

2. Digitize

For embroidered and woven patches we convert your art to a stitch file. Free on orders $150+.

3. Stitch or Mold

Tajima multi-head production for embroidered/woven, mold tooling for PVC, laser etching for leather.

4. Border

Merrowed, hot-cut, or laser-cut depending on shape.

5. Backing

Sew-on, iron-on, velcro, adhesive, button loop, or magnetic. Applied in-house.

6. QC & Ship

Every order inspected. Tracked shipping nationwide, local pickup in Huntington, NY.

Why EmbroideryLI

We are not a broker. Every patch we sell is produced on equipment we own and operate at 205 E Main St in Huntington, NY. That gives us four real advantages over patch resellers and overseas drop-shippers:

  • No minimums. We will run a single patch if that is what you need. Most overseas vendors require 50-100 minimum.
  • Live preview. See your art rendered before payment. Catch problems before stitching.
  • Free digitizing on $150+ orders. The stitch file is yours to keep for any future order with any vendor.
  • In-house QC. Every patch is inspected before it ships. Reject rate near zero.

For Long Island customers, local pickup is available and we will meet in person for high-stakes department, agency, or team projects.

Featured Patch Industries

Who we make patches for every week.

Fire DepartmentsPolice AgenciesEMS / ParamedicMilitary UnitsBoy & Girl ScoutsYouth & Adult SportsApparel BrandsMorale / Tactical Crews

Patch FAQ

Top ten questions we get every week.

Do you have a minimum order on custom patches?+

No. We have no minimum on any patch type. Order one or ten thousand, the per-piece price scales with quantity but we never refuse a small run.

How much do custom patches cost?+

Embroidered pricing starts at $12 for 2-inch, $16 for 3.5-inch, and $22 for 5-inch. Backings add $2-$3. PVC, leather, and chenille run slightly higher due to mold or material costs. Get an exact quote in the configurator.

What is the difference between embroidered and woven patches?+

Embroidered uses thicker thread stitched on top of a twill base, creating a raised texture. Woven uses thinner thread woven into the patch itself, producing higher detail and a flat, smoother surface. Embroidered is more durable; woven holds finer line work.

Which patch type is best for outdoor or tactical use?+

PVC patches are waterproof, UV-stable, and resist abrasion better than thread. They are the standard for military, law enforcement, and outdoor gear.

Can I put my patches on a hat?+

Yes. Leather patches dominate the hat market right now, but embroidered and woven patches also apply cleanly to caps via sewing or heat application.

What backing should I choose for a uniform?+

Sew-on for permanent placement (fire, police, EMS, military). Velcro for swap-on/swap-off uniforms with patch panels (tactical, morale).

What is digitizing and do I need it?+

Digitizing converts your logo into a stitch file the embroidery machine reads. It is required for embroidered patches and is free on patch orders of $150 or more.

How long does production take?+

Embroidered and woven patches typically ship in 7-10 business days after artwork approval. PVC patches require mold tooling and add 7-10 days. Rush available on most types.

Will iron-on patches stay on through the wash?+

Iron-on adhesive holds for casual wear and dozens of washes, but for permanent attachment we recommend sewing the perimeter after pressing.

Can you match my exact thread or PVC color?+

Yes. Embroidered patches use the Madeira and Isacord thread libraries (over 400 colors). PVC patches mix Pantone-matched colors per mold layer.

Ready to Build a Patch?

Start in the configurator or call the shop direct.

(631) 458-3842