Embroidered Patches
Create your Artwork Instantly
- Easily create your artwork using only text and your imagination
- Add a logo or design element to your artwork if you desire
How it Works
- Receive a Digital Proof within 1 business day. Approve or request changes from your customer account.
- If Sample Photo is selected, receive it within 5 business days of approving your digital proof.
- Once all approvals are complete, Turnaround starts and your Ship Date is posted to your customer account.
I needed a rush job on my labels to get my customer orders out after another company let me down with delays. I chose the 3 day rush option and they delivered on time as promised. The price was reasonable and the quality of my label was impeccable. I can’t say enough about this company!!
Quick, easy and great results!
Labels came out great, very impressed. Thank you!
Embroidered Patches for Hats
Custom embroidered patches are one of the most popular ways to brand hats, caps, and beanies. Unlike direct embroidery — which requires specialized equipment and can distort thinner hat materials — an embroidered patch is produced separately and then sewn or ironed onto the hat. This gives you a clean, consistent look across your entire inventory.
Our hat patches are available with iron-on backing for quick application or sew-on attachment for maximum durability. The most popular sizes for hat patches are 2 to 3 inches, fitting comfortably on the front panel of structured caps. We produce patches with either a classic merrow border (the raised, stitched edge) or a clean laser-cut edge for a more modern look.
Whether you're creating branded merchandise, team caps, or promotional giveaways, custom embroidered hat patches deliver a professional, tactile finish that customers notice.
Embroidered Patches vs Woven Patches: Key Differences
Both embroidered and woven patches are fabric-based, but the production method creates a very different look and feel.
Embroidered patches are made by stitching colored thread onto a twill backing with an embroidery machine. The thread sits on top of the backing, creating a raised, three-dimensional texture you can feel. Embroidered patches have a classic, substantial look that's bold and eye-catching. Best for: larger designs, bold logos, and designs where texture matters.
Woven patches are produced on a loom, with the design woven into the fabric itself. This creates a thinner, smoother patch with much finer detail — small text, intricate lines, and subtle color gradients come out crisp and clear. Best for: detailed logos, small text, and designs where precision matters more than texture.
Quick comparison: • Detail level: Woven wins — can reproduce text as small as 1mm • Texture: Embroidered wins — raised, tactile surface • Thickness: Woven is thinner, sits flatter on garments • Cost: Similar at most quantities • Durability: Both excellent; woven slightly more resistant to snagging
Frequently Asked Questions
Q: How much do custom embroidered patches cost?
Pricing depends on size, complexity, and quantity. Small patches (2-3 inches) start around $0.50-1.00 each in quantities of 100+. Volume discounts for larger orders. Request a free quote for exact pricing.
Q: What's the difference between embroidered and woven patches?
Embroidered patches have a raised, textured surface stitched onto a twill backing — classic and tactile. Woven patches are thinner and flatter, reproducing finer detail. Choose embroidered for bold designs, woven for intricate details.
Q: Can embroidered patches be ironed on?
Yes. We offer iron-on backing with heat-activated adhesive. For frequently laundered items, we recommend adding a few stitches around the border for permanent attachment, even with iron-on.
Q: What file format do I need for my patch design?
Vector files (AI, EPS, PDF) work best. If you only have JPG or PNG, our design team converts it to production-ready format at no extra charge. Free digital proofs before manufacturing.
Direct Embroidery Not Possible?
Make a Custom Embroidered Patch
At times, even highly skilled direct embroidery professionals may encounter challenges that hinder the success of a project. These challenges may stem from factors such as size, intricacies, or the specific location for direct embroidery. Although there are some limitations in achieving intricate details with embroidered patches, we often discover the possibility of transforming rejected direct-to-garment projects into stunning embroidered patches.
Merrowed Edge
VS
Laser cut
When deciding between a merrowed edge and a laser cut for your embroidered patches, it's es- sential to consider the specific needs of your project. Merrowed Edge:
The merrowed edge option is the most common and a fundamental choice for embroidered patches. This classic technique involves a 1/8” thick border that wraps around the front and back of the patch. It provides a traditional and timeless look, making it a staple in patch design.Laser Cut Edge:
On the other hand, a laser cut edge is crafted using an ultrasonic cutter, ensuring that all edges are sealed and resistant to fraying. This method is preferred when the patch design is too intricate for the merrowing machine or when the patch's size makes merrowing impractical and not aesthetically appealing.
Preview Your Embroidered Patches:
Photo Sample Before Production
To ensure your patch design is accurately translated from digital to embroidery, we recommend adding a free photo sample to your order. This allows you to confirm that the design elements and colors are correct before finalizing. Opting for this service extends the processing time by four business days, so it might not be ideal for urgent orders. However, it's a valuable step for those who have time, ensuring your patches meet your expectations. Once you approve the sample, we'll update the 'ship by' date in your account, informing you of the completion and shipping timeline. 
Backing Options for Embroidered Patches:
Choosing the right backing for your project can be overwhelming due to the variety of options available. Here's a simplified guide to five popular backing choices:- Plastic Backing:
Included in our base pricing, this standard option is ideal for patches meant to be sewn onto fabrics.- Iron-On Backing:
A favored choice for easy application. Use a heat press or iron to activate the glue on the patch's back, bonding it to your garment. Iron-on patches are not as enduring as sewn ones but can withstand several washes and attach permanently.- Peel & Stick Backing:
Great for simplifying the sewing process. Just peel off the paper layer, place the patch on the fabric, and sew. It's a time-saver, eliminating the need for double-sided tape. This versatile backing also allows temporary attachment, transforming patches into unique embroidered stickers.- Hook & Loop Backing:
Long popular among military, law enforcement, and firefighters, this backing is gaining widespread appeal for its versatility.- Hook Side Only: Includes only the hook side (the rough part) securely sewn onto the patch. This ensures a strong attachment without detachment during frequent use. Ideal if you already have the loop side (the soft part).
- Hook and Loop (Both Sides):
Comes with both hook and loop sides. The hook side is securely attached to the patch, and you also receive the loop side, pre-cut to fit the patch. Sew the loop side onto your chosen item, then attach the patch with the hook backing.
Embroidery Elegance: A Color Showcase
With our base pricing, we include up to 8 thread colors for your patch, with the option to expand to 12 colors under our custom pricing. We encourage you to explore beyond just black and white to make your patch as unique as you are. Our dedicated art team is committed to ensuring the best possible thread color match to the colors in your artwork. If your design requires specific Pantone colors, please indicate this in the comment section while placing your order. For reference, here is a link to our digital color chart.
Price Quotes
Give us the opportunity to earn your higher quantity embroidered patch orders by requesting a custom price quote. Any order over 10,000 pcs will receive a customized quote based on your unique design and specifications so you receive the lowest possible price. Request a embroidered patch quote and a representative will reply with your quote via email within 2 business days.
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