Custom PVC Patches
Molded rubber-like patches. Waterproof, UV-stable, abrasion-resistant. The standard for military, tactical, and outdoor.
2D vs 3D PVC
All PVC patches start from a mold. The mold determines whether the patch reads 2D or 3D. The difference is depth.
2D PVC: The mold has a single working depth. Color separation is achieved by surface boundaries between PVC pours, but every color sits at the same elevation. The patch reads flat with raised outlines between color zones. Cleaner for text-heavy designs, simpler logos, and budget-conscious orders.
3D PVC: The mold has multiple working depths sculpted into it. Different areas of the design rise and fall, producing a relief-carved look. 3D is the premium choice - logos with shading, characters, equipment renderings, and detailed unit insignia all benefit from the dimensionality. Expect a 10-15% upcharge.
Mold Tooling Explained
Every PVC patch design requires a custom aluminum mold. We CNC-machine the mold from a 2D or 3D digital model of your art. Once cured, the mold becomes a reusable tool that we keep on file for reorders.
The setup fee covers mold machining and is a one-time cost per design. Typical setup ranges $80-$200 depending on size and complexity. After the first run, reorders from the same mold incur no additional setup charge - you only pay the per-piece price.
Plan around the mold lead time. Embroidered patches ship in 7-10 business days; PVC adds another 7-10 days for the mold step on the first order. Reorders run on the standard production schedule.
Why Tactical, Military, and Outdoor Use PVC
PVC is the field-grade patch material. Four reasons it dominates the use cases that beat patches up the hardest:
- Waterproof: Closed-cell plastic. Mud, rain, blood, salt water - none of it penetrates.
- UV-stable: Sun exposure does not bleach the color the way it does thread.
- Abrasion-resistant: Rubs against gear, plate carriers, and packs without losing definition.
- Wipeable: A wet rag cleans dirt off without damaging the patch. Embroidered thread holds dirt.
Result: PVC is the default for morale patches, military unit patches, tactical gear, outdoor brand patches, and emergency response gear.
Pricing
| Size | 2D PVC | 3D PVC |
|---|---|---|
| 2" | $14 | $16 |
| 3" | $17 | $20 |
| 3.5" | $19 | $22 |
| 4" | $22 | $26 |
| 5" | $28 | $33 |
Velcro backing included on PVC. One-time mold fee $80-$200 applied to first order. Reorders no setup.
PVC Patch FAQ
What is a PVC patch?+
A PVC patch is molded from polyvinyl chloride - a flexible, rubber-like plastic. The art is sculpted into an aluminum mold, liquid PVC is poured into the mold layer by layer in different colors, then cured. The result is a flexible, waterproof patch with a rubbery feel.
What is the difference between 2D and 3D PVC patches?+
2D PVC patches have all color layers at the same depth - flat, like a coin face with raised color separation. 3D PVC patches use multiple sculpted depths so portions of the design rise and fall like a relief carving. 3D costs slightly more and produces a more premium, dimensional look.
Are PVC patches truly waterproof?+
Yes. PVC is a closed-cell plastic, not a fabric. Water, sweat, mud, and oil cannot penetrate it. Submersion does not damage the patch. This is why PVC dominates military, tactical, outdoor, and marine applications.
How UV-resistant are PVC patches?+
Standard PVC formulations include UV inhibitors that prevent fading and yellowing for years of outdoor exposure. Compared to embroidered thread (which can fade in heavy sun within 12-24 months), PVC holds color significantly longer.
How many colors can a PVC patch have?+
Each color is a separate mold pour, so cost and complexity rise with color count. Most PVC patches stay between 4 and 8 colors. We can do up to 14 colors but pricing scales accordingly. Pantone matching is standard.
What is the lead time for PVC patches?+
PVC requires a custom mold tool to be machined for your design. That mold step adds 7-10 business days on top of standard production. Total turn is typically 3-4 weeks. Reorders from the same mold ship faster because the tool already exists.
Is there a setup fee for the PVC mold?+
Yes. A one-time mold setup fee covers the aluminum tooling. The fee scales with patch size and complexity, typically $80-$200. We retain the mold for future reorders at no additional cost.
What backings work with PVC patches?+
Velcro (hook backing) is the most common and is the tactical standard. Sew-on, iron-on, and adhesive are also available. PVC accepts all standard backings; the only restriction is iron-on temperatures - we use a compatible adhesive that does not soften the PVC.
Related Patches
Build Your PVC Patch
Send your art. We'll quote mold and per-piece pricing within 24 hours.
Or call (631) 458-3842