Custom patches for clothing, caps, bags and uniforms – embroidered, woven, chenille or printed, finished with the border and backing your product needs. As a patch manufacturer with our own machines in Bulgaria, we digitise, produce and inspect every design in-house.
What a custom patch is
A patch is a complete badge in its own right: the design is built on a base fabric, framed by a sealed edge and given a backing, ready to be stitched, ironed or fastened onto the product. Where an inside label is read by the wearer, a patch is seen by everyone else – on the chest of a hoodie, the front of a cap, the shoulder of a uniform or the flap of a backpack. The technique you choose shapes how your logo reads from across the room and how it looks after years of wear and washing.
Because our digitisers sit next to the machines they programme, we can test a stitch file, adjust densities and approve colours on the spot, which keeps sampling quick and results consistent.
Patch techniques at a glance
| Technique | Surface | Detail level | Ideal for |
|---|---|---|---|
| Embroidered | Raised, textured thread | Bold logos, medium detail | Caps, jackets, workwear, uniforms |
| Woven | Flat, fine and light | Small text, thin lines | Sleeve logos, sportswear, small badges |
| Chenille | Soft, looped pile | Large, simple shapes | Varsity jackets, letters, mascots |
| Printed / sublimated | Smooth, full colour | Photos, gradients, unlimited colours | Event, club and illustrated designs |
Embroidered patches
Stitched in polyester or rayon thread on a twill base. With partial coverage the twill becomes part of the design; with full coverage the surface is entirely thread for a dense, raised look. Polyester thread keeps its colour well through frequent washing and sunlight, while rayon has a slightly richer sheen. 3D puff embroidery stitches over foam to lift letters several millimetres off the surface – a favourite for caps and streetwear – and metallic threads can add accents.
Woven patches
Produced on jacquard looms with fine yarns, on the same principle as our woven labels. Thinner threads capture small lettering, delicate outlines and subtle shading with precision, and the patch stays flat and lightweight. When your logo contains text smaller than about 3 mm, woven is usually the clearer choice.
Chenille patches
Looped yarn creates a soft, towel-like pile, normally set on felt and outlined with embroidery. It is the classic collegiate look for initials, numbers and mascots. Chenille shines on bold shapes and generous sizes; fine detail is added through the embroidered outline.
Printed and sublimated patches
For photographic artwork, colour gradients or many colours, dye sublimation on polyester twill gives unlimited colour on a smooth surface. Framed with a merrowed or embroidered border, a printed patch keeps the familiar patch character.
Edges and borders
- Merrowed border – a thick overlocked edge wrapped around the patch; hard-wearing and traditional, best on circles, ovals, squares and other simple outlines.
- Laser cut – follows any contour, including tight inner corners, and seals synthetic fibres as it cuts.
- Heat cut – a hot blade or die cuts and fuses in a single step for a neat finish on woven and printed patches of medium complexity.
Every edge is sealed so it stays clean on the garment and in the wash.
Backings and how patches are attached
| Backing | Application | Recommended for |
|---|---|---|
| Sew-on | Stitched around the edge | Workwear, uniforms, heavily washed garments |
| Iron-on / heat-seal | Heat press or domestic iron | Fast application in production; add a stitch for heavy washing |
| Hook-and-loop | Hook side on the patch, loop side supplied for the garment | Tactical, rescue and team wear with interchangeable patches |
| Peel-and-stick | Self-adhesive | Bags, packaging, giveaways – for non-washable items |
Patch sizes we produce most often
| Placement | Typical size (mm) | Suggested technique |
|---|---|---|
| Small sleeve or chest logo | 40 × 40, 50 × 30 | Woven or embroidered |
| Standard chest logo | 60 × 60, 70 × 50, 80 × 40 | Embroidered or woven |
| Cap front | 50 × 50 to 70 × 50 | Embroidered, 3D puff, woven |
| Shoulder / uniform emblem | 75 × 90, 80 × 100 | Embroidered with merrowed edge |
| Name tape | 100 × 25, 120 × 25 | Woven or embroidered, hook-and-loop |
| Back or varsity patch | 150–250 wide | Chenille or embroidered |
Sizes are measured across the widest and tallest points, border included. Most patches fall between 50 and 100 mm, and we make custom shapes outside that range too. Please give us the size the patch will actually be worn at: a design that looks sharp at 100 mm can lose detail at 40 mm in embroidery, and we will advise whether woven or printed suits a small format better. Our label size guide has more on proportions.
Colours and artwork
Embroidered patches typically use up to 10–12 thread colours per design, matched to Pantone references. Woven patches usually work with around 8 colours, set by the loom configuration. Printed patches have no practical colour limit. A vector file is ideal, but a sketch or a photo of an existing badge is enough for our design team to start.
Typical uses
- Streetwear and fashion brands: chest logos, cap fronts, sleeve badges.
- Corporate and workwear: company logos on jackets, polos and hi-vis outer layers.
- Clubs, schools and teams: crests, numbers, varsity letters.
- Outdoor and tactical: hook-and-loop identification and name tapes.
- Bags, backpacks and accessories: front badges and decorative details.
Production steps and what to send
- Send your artwork, finished size, the garment and the backing you prefer.
- We digitise the design and send a digital proof, typically within 24–48 hours.
- A physical sample lets you check colour, size and backing on the product.
- After approval, production typically takes 10–20 working days.
- We deliver across the EU without customs formalities; ask about express options for launch dates.
Minimums usually start at 1,000 pieces per design – contact us with your quantity.
Quality and materials
We work with OEKO-TEX certified materials, and recycled polyester options with GRS certification are available for sustainable collections. Each batch is checked for colour accuracy, stitch quality, edge sealing and backing adhesion. Patches complement leather labels on waistbands and silicone labels for a technical look.
Frequently asked questions
My logo has very small text. Which patch type should I choose?
A woven patch. Its finer threads render lettering below about 3 mm much more clearly than embroidery, and the patch stays flat.
Are iron-on patches strong enough for workwear?
Iron-on backing is convenient for fast application, but for garments washed often we recommend sew-on, or iron-on with an extra stitch around the edge.
What is 3D puff embroidery?
Embroidery stitched over a foam layer so the letters stand several millimetres above the surface. It is popular on caps and streetwear.
Can patches be removed and swapped?
Yes. With a hook-and-loop backing, patches can be exchanged on the garment, which suits team, rescue and tactical wear.
Can I get a sample before ordering?
Yes. We produce a physical sample for every patch type so you can check it before bulk production.
Tell us your logo, size and garment and we will recommend the right technique: [email protected], WhatsApp/Viber +359 876 766 050, or our contact page.