Custom Patch Options
Edges, sizing, embroidery coverage, backings, and thread colors
Our embroidered patches are the result of relentless attention to materials, threads, and mesh. Use this page to pick the right edge style, work out the size of your patch, and choose how much of the surface gets stitched — then jump to the detailed backing and thread color pages when you're ready to lock in the rest.
Built to a Higher Standard
Every patch we make uses premium thread, twill, and stabilizer backing. The result is consistent stitching, vivid color, and an edge that holds up to washing, ironing, and years of wear.
Each of the options below is included free or available as a small upgrade — you'll see them as choices in your free artwork proof, so nothing is locked in until you've seen exactly how it'll look.
Patch Sizing
How we measure your patch and quote the size
We size every patch using a simple average:
(Height + Width) ÷ 2 = Patch Size
Add the patch's largest height to its largest width, then divide by two. The result is the size we quote on. This keeps pricing fair across odd shapes — a tall narrow patch and a wide short patch with the same average dimension cost the same to stitch.
Embroidery Coverage
How much of the patch surface is stitched
Embroidery coverage is the amount of thread stitched across the surface of the patch. We quote on two tiers:
- Up to 75% coverage — twill mesh shows through in the background. Lighter, less expensive, and ideal for designs with open space, lettering, or a visible base color.
- 76-100% coverage — the entire surface is stitched. Heavier and denser, with no visible mesh. Best for full-color illustrations, dense logos, and tactical or military patches.
Coverage affects both price and feel — fully embroidered patches are stiffer and heavier than partial-coverage patches.
Choose the edge style that fits your needs
Patch Edge Options
Both included free on every order
Merrowed Edge
A thick, overlocked stitched border around the perimeter — the classic patch look. Works best on standard shapes like circles, squares, rectangles, and shields. The raised thread border adds durability and a tactile finish.
Hot Cut Edge
A clean, laser-cut edge that follows the exact outline of your artwork. The right choice for irregular shapes, mascots, logos with intricate outlines, or any design where a thick merrowed border would obscure the silhouette.
Iron-on, PVC, Velcro, peel and stick, and more
Patch Backings
We offer eight backing options — most included free.
The right backing depends on how the patch will be attached and how often it needs to come off. No backing keeps the patch sew-on classic; PVC adds rigidity; Velcro lets recipients swap patches on and off uniforms, tactical gear, or kit; iron-on means no needle required.
252 thread colors, 72 mesh colors, plus neon and metallic
Thread and Mesh Colors
Mix and match from our full color reference.
Our standard chart includes 252 embroidery thread colors and 72 twill mesh colors, with neon and metallic threads available as upgrades. Up to 7 colors are included free in every design — additional colors are $.10 each.
Our services include…
- FREE artwork & design with unlimited revisions
- FREE UPS Air shipping — guaranteed
- Delivery in 14 business days or fewer
- 100% quality & workmanship guarantee
- Ready to talk? Call +1 800-257-9664