Manufacturing
Our Custom Patch Manufacturing Process
1. Artwork review
Our patch manufacturing process starts with your artwork. First, our team checks the size, colors and fine details against the patch type you chose.
Some designs need small changes to look sharp. For example, text under about a quarter inch can blur in thread, so we may suggest a bolder font or a woven patch instead.
2. Digitizing and proofing
Next, embroidery designs are digitized. That means a designer converts the artwork into a stitch file that tells the machine where every stitch goes.
For PVC patches, the design is separated into color layers for the mold instead. In both cases, you receive a digital proof showing size, colors and border. Production only begins after you approve it.
3. Production
Embroidered patches are stitched on multi-head machines. The twill base is hooped tight, and each head sews the same design at once for consistent results.
PVC patches are made by filling a custom mold with liquid PVC color by color, then curing it with heat. Woven patches come off a loom, while chenille uses looped yarn on felt.
4. Borders and cutting
After stitching, each patch gets its edge. A merrowed border wraps thick thread around round, square or shield shapes. Meanwhile, heat-cut and laser-cut edges follow detailed custom shapes.
5. Backing
Then we add the backing you chose. Iron-on patches get a heat-seal adhesive layer. Hook-and-loop patches get a sewn hook side, and sew-on patches are left clean on the back.
6. Quality inspection and packing
Finally, every batch is checked against your approved proof. Inspectors look at stitch coverage, colors, size, border quality and backing. Patches that miss the mark are pulled before packing.
What Our Quality Checks Cover
- Stitch coverage, density and tension
- No loose threads, jumps or gaps
- Colors compared to the approved proof
- Correct size within normal production tolerance
- Even merrowed, heat-cut or laser-cut edges
- Backing applied flat and fully bonded
- PVC color fills clean with no bubbles
- Correct quantity counted before packing
Want to learn more about the methods behind each style? Read how custom patches are made, or compare options in our types of patches guide.
Put Our Process to Work on Your Design
Send us your artwork and project details. Our team will review your design and reply with a quote and next steps.