The Ultimate Guide to Custom Patch Types
Not all patches are created equal. The type of patch you choose affects how it looks, how long it lasts, and what it costs. This guide explains every major patch type — embroidered, woven, PVC, chenille, printed, and more — so you can make the right choice for your project.
1. Embroidered Patches
✅ Best For
- Logos and crests
- Military & tactical
- Club & team patches
- Jacket back patches
⚠️ Limitations
- Not suited for very fine detail
- Limited to ~15 colours
- Minimum size ~1.5"
Embroidered patches are stitched using industrial embroidery machines. The raised, textured look gives them a premium, handcrafted feel. Thread coverage can be 50%–100% depending on the design density you choose.
2. Woven Patches
✅ Best For
- Intricate designs
- Small text (under 6pt font)
- Labels inside garments
- Fine detail photography-style
⚠️ Limitations
- Slightly less durable than embroidered
- Flat, less raised texture
Woven patches use thinner threads on a loom, creating a flatter surface that captures much finer detail than embroidery. They're the go-to choice for clothing labels and any design with intricate line work.
3. PVC / Rubber Patches
✅ Best For
- Outdoor & tactical gear
- Waterproof applications
- 3D novelty patches
- Morale patches
⚠️ Limitations
- Heavier than fabric patches
- Not suited for delicate fabrics
PVC patches are moulded from flexible rubber and are completely waterproof and UV-resistant. Their 3D structure can capture incredible detail. Extremely popular in the military, law enforcement, and outdoor communities.
4. Chenille Patches
Made with thick, looped yarn, chenille patches have a distinctive fluffy, soft texture. The classic varsity letterman patch. Perfect for large letters, numbers, and mascot shapes on school and sports jackets.
5. Printed Patches
Printed patches use digital sublimation or screen printing to reproduce photographic detail and unlimited colours. They are cost-effective for short runs but less durable under heavy washing compared to embroidered or woven options.
Quick Comparison Table
| Type | Detail Level | Durability | Best Use |
|---|---|---|---|
| Embroidered | Medium | ⭐⭐⭐⭐⭐ | Logos, crests |
| Woven | High | ⭐⭐⭐⭐ | Fine detail, labels |
| PVC/Rubber | High (3D) | ⭐⭐⭐⭐⭐ | Tactical, outdoor |
| Chenille | Low (shapes only) | ⭐⭐⭐⭐ | Varsity, sports |
| Printed | Very High | ⭐⭐⭐ | Short runs, photos |
Not sure which type to choose?
Contact us and we'll recommend the best option for your design and budget.
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