Size & Shape

Some standard sizing for patches:

• Small: 2–3 inches (ideal for hats or collars)
• Medium: 4–6 inches (suitable for jackets or bags)
• Large: 7+ inches (great for back patches or large surfaces)

Shape Options

• Traditional Shapes: Common shapes include circular, rectangular, square, and oval. Choose a shape that complements your design.
• Custom Shapes: For unique logos or designs, consider custom die-cut shapes. Ensure the complexity of the shape matches the patch's intended size.

How to determine your patch size:

• Measure the length and width of your desired patch
• Add these two numbers together, and then divide by 2
• The result is rounded up to the nearest half or whole number to give you the perfect size for your patch

Design Considerations

• Complexity of Design: Intricate designs may require larger patches to maintain detail. Simple logos can work well in smaller sizes.
• Text Size: If the patch includes text, ensure the size is large enough for readability. Typically, text should be at least 0.25 inches tall.

The size and design of your patch determine the patch’s embroidery coverage over the surface of the patch.

50% embroidered patch is good for simple, text-only designs wherein at least half of the twill backing is visible.

75% embroidered patch allows larger, more intricate artwork, and covers more of the twill.

100% embroidered patch is ideal for intricate designs and logos wherein the twill is entirely invisible. This also offers the most detail possible on a patch.

The Patch background material is important if you are expecting some of this background to show on your patch. Both come in a variety of standard colors.

Twill Background

Twill is a woven fabric known for its subtle diagonal ridged pattern. This pattern gives twill some unique properties that make it work very well for patches. The tight weave makes twill fabric for patches quite sturdy and stable during the embroidery process.

Felt Background

The surface of felt has plush fibers, which is very soft and comfortable. The edge of the felt patch are generally trimmed, and embroidery edges can also be used.

7 colors included at no additional charge!

• If your patch design uses non-specific, generic colors (red, blue, green, yellow, black, white, etc.), just specify these colors and we will use a standard color for your proof.   
• A more specific way to choose colors is to match them up to the Pantone color system, especially if you have a company logo that uses a specific shade of blue. Although not every Pantone color is available, many are, and we can help you get the closest available match.
• When it comes to metallic colors, Glitter thread shines with a reflective sparkly appearance — silver, gold, and copper are possibilities.
• Neon threads are a creative and imaginative choice if you want a striking patch design -- Neon green, cyan, pink, and yellows are eye-catching options.

Laser cut borders, sometimes known as satin stitch borders or hot cut borders, are the most commonly used patch border. This method is done by embroidering or stitching the border directly onto your patch, and then cutting the patch as close as possible around the border with a laser or hot scissors. The borders themselves are typically between one-sixteenth and one-eighth of an inch thick. 

Laser cut borders are great for patches with complex or unique shapes, since the border is embroidered before cutting out the patch, and the hot cutting tools can more precisely create extreme shapes and angles. To prevent fraying of what little material is left on the outside of the stitch, the fabric is usually melted (called “border baking”), creating a clean wax-like heat seal on the outside. 

Merrow borders, also known as overlock sewing borders, provide the most traditional embroidered look to any patch. The Merrow stitch is named after the Merrow® sewing machine, which was the first type of sewing machine to popularize the overlock stitch in the 1930s. The overlock stitch wraps around the outside of the patch, forming a wrapped thread border two to four millimeters wide. This technique adds weight and durability to the patch material and eliminates the possibility of frayed edges. 

Merrow borders work best on woven, traditional-looking embroidered patches because the wrapped thread border lends itself to that particular style, and they can even add an old-school vintage look to motorcycle or name tag patches. Because of the thick border and overlocked stitch, this type of border is ideally used on very simple shapes, i.e., circles, triangles, rectangles, or shield-shaped patches with no sharp inside angles. 

From small town club meetings and summer camps to large-scale events and parades, Southwest Emblem can help you decide which type of custom patches and borders will be the best choice for your desired look. We are ready to provide you with the best quality custom-made patches, lapel pins, medals, and embroidery products, so contact us today!

Patches are typically created with no added backing material. It is easy to see the tied-off embroidery threads on the back of the patch. An unbacked patch is very flexible and easy to sew on. This is standard from most patch manufacturers. However, Southwest Emblem upgrades your patch to include plastic backing, included in the price! If you prefer no backing, just let us know.

Most regular, embroidered, or dye-sublimated patches have plastic backing in order to give the patch rigidity and help keep its shape over time. The plastic is thin enough that the patch is still malleable and it can be sewn onto the fabric of your choice.

Pros

Plastic backed patches hold their stiffness and shape over time, and are still thin enough to sew onto different garments.

Cons

Plastic backed patches don’t have many cons—the plastic back adds nothing but more durability and maintain the quality of your patch for years to come.

Heat sealed patches are backed with a thin, shiny coating that will melt upon contact with heat. When pressed with an iron, the back of these patches will form an adhesive bond between the patch and garment.

Pros
Heat sealed patches, sometimes called iron-on patches, can usually be adhered with a home iron and should withstand up to twenty or thirty cycles in the wash.

Cons
Certain heat sealed patches can’t be properly attached with a home iron, and in these instances a heat seal machine may be required for the heat, pressure, and time to correctly seal the patch. Heat sealed patches are ideal for most materials, but do not work with nylon or other synthetic fabrics.

Although this type of backing is not as durable as other patches, adhesive backings are simple and straightforward. Backings with a sticky adhesive are made from glue pressed onto the back of a patch and overlaid with peelable paper to be removed at the time of application. These patches are similar to stickers, but the glue used is much stronger than normal sticker glue.

Pros
Adhesive patches are simple, straightforward, and quick to apply.

Cons
This type of backing is far less durable than other patch options and won’t withstand multiple cycles in the wash.

Often used for military and law enforcement patches, hard hook and loop patches have a backing that consists of tiny hooks and loops very similar to the rough side of velcro. This allows the patch to be securely connected to a soft velcro backing that is usually purchased in conjunction.

Soft Pile Hook and Loop Patches

Similar to hard hook and loop patches, the backing of these patches is made out of the fuzzier, soft part of velcro and made to be attached to a hard hook and loop fastener that is usually sewn onto a military or law enforcement uniform. Both hard hook and loop and soft pile hook and loop patches are ideal for tactical needs where the patch may need to be replaced or reapplied frequently.

Pros
Hard hook and soft pile hook patches are ideal for law enforcement and military uniforms, making reapplication easier than sewing and resewing patches or utilizing heat and glue.

Cons
When purchasing hard hook or soft pile hook patches, you will also need to purchase the opposite backing to sew onto the garment for application — creating an extra step.

Magnet backed patches use a thin sheet of magnetic material attached to the back of the patch. Once applied, the patches can adhere to anything metal. To create a removable patch on wearables, use an opposing magnet behind the garment material.

Pros
Magnetic backing is durable and secure, creating several options for what your patch can attach to, whether it be a garment or an object.

Cons
Sewing an opposing magnet into the connecting fabric is an extra step that may seem unnecessary when compared to choosing sew on or heat sealed patches.

These patches are ideal for patches that may need to be replaced, reapplied, or switched around, such as those applied to bags, jackets, and uniforms. Pin backing patches have one or more straight pins sewn inside the layers of backing, allowing the patch to be used as a brooch. Butterfly clutches are used to secure the patch on the other side of the material.

Pros
Like hard hook and soft pile hook patches, pin backing patches are great for military, law enforcement, or school uniforms, allowing you to remove, reapply, and change positions without ruining the patch.

Cons
The butterfly clutches used to secure the patch may get lost, fall off, or bend and break with excessive wear.