How Custom Patches are Made
When most people think of custom patches, they imagine a simple logo sewn onto fabric. The truth is, creating a high quality patch involves careful design, specialized machines, and materials chosen for specific needs.
If you have ever ordered patches that faded, peeled, or did not meet expectations, it is usually because the process was not understood clearly. This guide explains how custom patches are made so you know exactly what to expect and how to choose the right patch type for your needs.
More Details
Before exploring the process, here are the most frequent challenges customers experience
Choosing the wrong patch type for example, ordering woven patches when an embroidered design was needed
Durability issues such as patches that fade, fray, or peel after a few washes
Application mistakes like using iron on patches where a sew on would last longer
Sizing and edges including unclear borders, wrong dimensions, or finishes that do not match the intended style
Understanding these problems is the first step toward finding reliable solutions, which is exactly what professional manufacturers like Custom Patches by Fineyst provide.
The Step by Step Process of Making Custom Patches
1. Designing the Patch
Every patch begins with a design file. Designers convert your logo or artwork into a digital embroidery ready format using specialized software. This step determines
The patch type, such as embroidered, chenille, woven, or PVC
How fine details will translate to stitching or molding
Which colors, textures, and finishes will look best
A strong design is the foundation of a durable, professional looking patch.
2. Choosing the Right Patch Type
Not all patches are created equal. Each type serves a different purpose
Embroidered patches offer raised thread texture and durability, great for uniforms and branding
Chenille patches provide a soft three dimensional look, perfect for varsity jackets
PVC patches are flexible, waterproof, and fade resistant, ideal for outdoor gear
Woven patches deliver smooth surfaces and detailed color shading
Velcro patches allow quick attach and detach, common in military and tactical gear
Iron on patches come with heat activated adhesive for simple application
Sew on patches provide a permanent solution for heavy use clothing
Choosing the right type prevents problems such as peeling, fading, or mismatched styles.
3. Preparing Materials and Machines
Once the design and type are finalized, manufacturers prepare
Fabric bases including twill, felt, or other sturdy textiles
Threads such as polyester or rayon for embroidery
PVC compounds for molded patches
Computerized machines then read the design file and stitch or mold the pattern with precision. This ensures every patch is consistent and professional.
4. Embroidery and Stitching Techniques
For embroidered patches, multiple stitch types bring designs to life
Satin stitch creates clean borders
Fill stitch covers larger areas
Chain stitch adds texture
Edges are finished with either
Merrowed borders which provide a classic overlock finish
Laser cut edges which deliver sharp modern outlines
For PVC, colored material is injected into molds to create waterproof durable designs.
5. Adding the Right Backing
Backing determines how the patch attaches
Iron on uses heat activated adhesive
Velcro relies on a hook and loop system
Sew on requires stitching for permanent attachment
Selecting the correct backing prevents issues such as patches falling off too soon.
Iron-on backing contains heat-activated glue, solving the problem of difficult application for customers who don’t sew.
Velcro backing uses hook-and-loop fasteners, providing flexibility for users who need to remove or switch patches frequently.
Sew-on backing leaves the patch with no adhesive, ideal for permanent attachment.
Choosing the right backing solves the problem of patch detachment and wear over time.
6. Quality Control and Packaging
Before shipping, each patch is inspected for
Accurate colors
Clean edges
Strength and durability
Patches are then packaged flat to protect them during shipping.
Why Understanding the Process Matters
Knowing how custom patches are made helps you
Avoid poor quality results
Choose the right type for your purpose
Communicate your needs clearly with your supplier
Example 1 A sports team wants patches for jerseys. If they choose iron on, the patches may peel after a few washes. Sew on embroidered patches would last much longer.
Example 2 A military unit needs patches that can be swapped easily. Velcro patches solve this need far better than permanent options.
Final Thoughts
Custom patches are more than fabric and thread. They are the result of design precision, material selection, and skilled craftsmanship. By understanding the process, you avoid costly mistakes and get patches that look sharp, last long, and match your exact needs.
At Custom Patches by Fineyst, we specialize in delivering tailor made patches whether embroidered, chenille, PVC, or woven crafted with durability and style in mind.
👉 Ready to bring your idea to life
Start your order today at custompatches.us.com
Ready to Create Your Own Custom Patch?
Helpful Comments
PatchLover22
March 15, 2025I tried this method with felt fabric and it worked beautifully! The patches have lasted through multiple washes.
CraftyMom
February 28, 2025Adding a thin layer of fabric paint around the edges really helps prevent fraying over time. Great tutorial!
DIYenthusiast
April 2, 2025For those having trouble with the adhesive, I found that pressing for 10 seconds, letting it cool slightly, then pressing again for another 10 seconds works better than one long press.