Custom Embroidered Patches
The classic patch. Polyester thread on twill base, merrowed border, built for decades of wear. From $12. No minimums.
Construction
An embroidered patch is built in layers. The base is a tightly woven twill - usually polyester for color stability, sometimes cotton for a vintage look. The design is stitched into the twill with polyester or rayon thread, the same fiber used in commercial machine embroidery. Once the design is laid in, a merrowed border wraps the patch perimeter with a dense overlock stitch that locks the edges and prevents fraying. Finally, a fabric or fusible backing seals the rear and accepts whatever attachment you choose - sew-on, iron-on, velcro, adhesive, or button loop.
We run Tajima multi-head embroidery equipment, the same machines used by major patch manufacturers and uniform suppliers. Thread comes from the Madeira and Isacord libraries, giving you over 400 stock colors plus metallic and fluorescent options.
Detail Limits
Thread is a physical fiber with a real thickness. That puts a floor on how fine an embroidered patch can render. The practical minimums to plan around:
- Minimum line width: approximately 1mm. Anything thinner gets eaten by adjacent stitches.
- Minimum text height: roughly 0.2 inches (about 6pt at finished size). Below that, lettering blurs.
- Color count: up to 9 colors per patch without surcharge. More are possible but require careful digitizing.
- Gradients: not supported - thread is solid color. We can approximate with adjacent thread shades, but true photographic gradients require sublimated patches.
If your art has hairlines, fine serifs, or photographic gradients, woven or sublimated patches will represent it better. For typical logos, monograms, badges, and emblems, embroidered is the right call.
When to Choose Embroidered Over Woven
Both embroidered and woven patches use thread, but the construction differs. The choice usually comes down to four factors:
- Durability: Embroidered wins. Raised stitching on twill survives decades of industrial laundering. Woven is thinner and flatter, more vulnerable to abrasion.
- Texture: Embroidered is raised, dimensional, and tactile. Woven is flat and smooth.
- Detail: Woven holds finer line work and smaller text. Embroidered handles bold, chunky logos better.
- Cost: Embroidered is cheaper in small runs. Woven cost-equalizes at higher volumes.
Rule of thumb: uniforms, badges, and anything that needs to survive a beating - embroidered. Fashion brands, small detailed logos, retail tags - woven.
Pricing
| Size | Sew-On | Iron-On | Velcro |
|---|---|---|---|
| 2" | $12 | $14 | $15 |
| 3" | $14 | $16 | $17 |
| 3.5" | $16 | $18 | $19 |
| 4" | $18 | $20 | $21 |
| 5" | $22 | $24 | $25 |
Single-unit pricing. Bulk discounts begin at quantity 25. Free digitizing on patch orders $150+.
Embroidered Patch FAQ
What is an embroidered patch made of?+
An embroidered patch is built on a polyester or cotton twill base, with the design stitched in polyester or rayon thread (typically Madeira or Isacord). A merrowed border wraps the outer edge and a fabric or fusible backing finishes the rear of the patch.
How much detail can an embroidered patch hold?+
Embroidered thread has a minimum line width of about 1mm. Text reads cleanly down to about 0.2 inches in height (roughly 6pt at finished size). Fine lines, photographic gradients, and hairline detail are better suited to woven or sublimated patches.
What size embroidered patches do you make?+
We produce embroidered patches from 1.5 inches up to 12 inches. Common sizes are 2", 3", 3.5", 4", and 5". Anything over 6 inches becomes a back panel and is quoted per project.
How durable are embroidered patches?+
Embroidered patches with merrowed borders are the most durable patch type we offer. They survive decades of wear, industrial laundering, and outdoor exposure. They are the patch standard for fire, police, EMS, military, and scouts for this reason.
What is a merrowed border?+
A merrowed border is a dense overlocked thread edge produced by a merrow machine. It wraps the perimeter, locks the stitching in place, and gives the patch its iconic raised edge. Merrowed is the default for round, square, oval, and shield patches.
Can I get an embroidered patch with iron-on backing?+
Yes. Iron-on (heat-activated adhesive) is a $2 add-on. It works on cotton, polyester, and fleece. Avoid iron-on for nylon, waterproof shells, or any technical fabric the heat will damage.
How long do embroidered patches take to produce?+
Standard turn is 7-10 business days after artwork approval. Rush production (3-5 days) is available for an add-on fee. Local pickup is offered at our Huntington shop.
Do you do free digitizing on embroidered patches?+
Yes. Digitizing - the conversion of your art to a stitch file - is included free on any patch order $150 or more. Below that threshold a one-time $125 fee applies and you keep the file for future orders.
Related Patch Types
Build Your Embroidered Patch
Upload art, pick a size, choose a backing. Live preview before checkout.
Or call: (631) 458-3842