Custom Patches
Made to Be Seen
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Printed Patches
Full-Color Digital or Screen Print
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Embroidered Patches
Classic High Quality
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Rush Service Available
Quick Production! when needed
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Different Backing
Iron-On, Heat-Press, Stitched
5 Star Reviews on Google
Proofs Sent Before Production
Trusted by Lululemon, UBC, Red Bull & more
Volume Discount
Custom Patches for Uniforms, Caps, Jackets and Merch
A patch does something a printed logo cannot: it adds physical texture. Stitched thread, moulded rubber or plush chenille all sit above the fabric surface, and that raised finish is why patches read as considered rather than applied, on a work uniform, a varsity jacket, a fitted cap or a streetwear drop.
We produce custom patches from our Vancouver facility for uniform programs, sports teams, schools, fashion labels and promotional runs, with production support across Canada and select U.S. cities.
Patches also travel: one design can move across jackets, caps, bags and shirts without being re-set for each fabric.
Embroidered vs Woven vs PVC vs Chenille Patches
The patch type determines the look, feel and level of detail your artwork can include. Use this guide to find the best option for your project.
| Type | How It’s Made | Best For | Artwork Limits |
|---|---|---|---|
| Embroidered | Polyester thread stitched onto a twill or felt base. | Uniforms, workwear, teams, clubs and caps. | Best for bold shapes and limited colours. Very fine details may close up. |
| Woven | Fine threads woven tightly together instead of being stitched on top. | Detailed logos, small lettering and fashion labels. | Holds finer details than embroidery and creates a flatter, smoother finish. |
| Printed | The design is printed onto a fabric base, then cut and finished. | Photographic artwork, gradients and complex illustrations. | Supports full-colour artwork and highly detailed designs with very few limitations. |
| PVC / Rubber | Soft PVC is moulded in raised layers to create a dimensional finish. | Outdoor gear, tactical apparel, workwear and products exposed to moisture. | Waterproof and fade-resistant. Best for 3D depth and bold blocks of colour. |
| Chenille | Looped yarn is applied to a felt base to create a plush, fuzzy surface. | Varsity and letterman jackets, school apparel and team clothing. | Best for large, simple shapes and letterforms. Not suitable for fine details. |
| Leather | Genuine or PU leather is laser etched, engraved or debossed. | Denim, caps, heritage products and premium apparel branding. | Best for simple marks and limited colours. The result is tonal rather than full colour. |
| Applique / Tackle Twill | Cut fabric shapes are stitched down around the edges. | Large names, numbers and letters on jerseys and jackets. | Best for bold letterforms and large-scale designs. Extremely durable. |
Embroidered patches
The classic format, and still the most ordered. Thread is stitched onto a twill base, giving a raised, textured surface that holds up through years of washing. Three things are worth deciding up front:
- Coverage: 50%, 75% or 100% embroidered. Partial coverage leaves the base fabric visible as part of the design and costs less; full coverage hides the base entirely.
- Border: a merrow border is the thick stitched edge on traditional patches and suits simple outlines. Laser-cut edges allow fully custom die-cut shapes with a clean thin finish.
- Dimension: 3D puff embroidery raises selected areas above the rest of the patch, which works well on caps and bold logo marks.
Printed patches
Where embroidery reaches its limit, printing takes over. The design is printed onto a fabric base and finished with a cut edge, which means gradients, photographic elements, fine lettering and unlimited colour count are all available. Printed patches sit flatter and lighter than embroidery, so they suit modern graphic branding, illustration-led designs and anything with small text.
For designs with one or two bold solid colours in larger quantities, screen printed patches are an economical alternative with strong ink coverage.
Iron-On, Sew-On and Velcro Patch Backings
The backing determines how the patch attaches to the item. Choose the option that best matches how the patch will actually be used.
| Backing | How It Attaches | When to Use It |
|---|---|---|
| Sew-On | Stitched securely around the edge. | Best for permanent placement on uniforms and workwear that are washed frequently. This is the most durable attachment option. |
| Iron-On | Heat-activated adhesive film. | Ideal for quick, no-sew application on jackets, caps and shirts. It is not recommended for waterproof or heat-sensitive fabrics. |
| Velcro (Hook and Loop) | The hook side is attached to the patch and the loop side is attached to the garment. | Suitable for patches that need to be removed or swapped, including tactical gear, name patches and rotating team badges. |
| Heat Seal | Industrial heat-press adhesive. | Provides a stronger bond than standard iron-on backing and is suitable for production runs applied professionally in-house. |
| Adhesive | Peel-and-stick adhesive backing. | Best for temporary applications such as events, trade shows and short promotional campaigns. |
| Magnetic | A magnet positioned behind the fabric. | Suitable for garments you do not want to pierce, including suit jackets and premium outerwear. |
| Pin or Button Loop | Clutch pin or stitched loop attachment. | Suitable for bags, lanyards, collectible patches and morale patches. |
Iron-on and heat-seal patches can also be stitched after application for additional security. This is a common choice for uniforms that undergo frequent or heavy laundering.
Patch Shapes, Sizes and Minimum Order
Patches are produced as circles, squares, rectangles, shields and fully custom die cut shapes that follow the outline of your logo. Minimum order: 10 pieces per design.
Size affects what your artwork can hold. A logo that reads perfectly at chest size can lose its fine lines at cap size, so we adjust detail and line weight to the finished dimensions rather than shrinking the file.
Sending artwork
- Vector (AI, EPS, SVG, vector PDF) is ideal, it scales to any patch size cleanly
- High-resolution PNG at 300 dpi at final size works for printed patches
- Pantone references if brand colour accuracy matters; thread and print colours are matched to them
- Avoid screenshots and images pulled from a website
Every order is confirmed with a digital proof showing shape, size, colours and backing before production begins. If your file needs rebuilding for stitching or cutting, we prepare it and show you the result first.
Custom Patches FAQ
What is the difference between embroidered and woven patches?
Embroidered patches stitch thicker thread onto a base fabric, producing a raised, textured surface with a traditional look. Woven patches use much finer threads woven tightly together, giving a flatter, smoother finish that holds far more detail. Choose embroidered for bold logos and uniforms, woven for small lettering and intricate artwork.
Which patch type is best for detailed logos?
Printed patches handle unlimited colour, gradients and photographic detail. Woven patches are the next best for fine lines and small text while keeping a fabric finish. Embroidery is the wrong choice for fine detail because stitch width sets a floor on how small a line can go.
What backing should I choose?
Sew-on for uniforms and anything washed frequently, it is the most durable. Iron-on for quick application on jackets and caps. Velcro when patches need to be swapped, such as name badges or tactical gear. Adhesive only for temporary event use.
Are iron-on patches permanent?
They hold well on standard cotton and blends, but heavy laundering will eventually loosen the adhesive. For garments washed weekly, stitch around an iron-on patch after applying it, or choose sew-on from the start.
Can you make patches in a custom shape?
Yes. Laser cutting allows fully custom die-cut outlines that follow your logo rather than fitting it into a circle or rectangle. A merrow border (the thick stitched edge on traditional patches) is available for simple outlines where that classic look is wanted.
What is embroidery coverage on a patch?
The proportion of the patch surface covered in stitching. At 50% or 75%, the base twill stays visible as part of the design and cost is lower. At 100%, thread covers the entire patch and no base fabric shows.
Do you offer bulk pricing on custom patches?
Yes. Setup is spread across the run, so unit cost drops as quantity rises, which is why patches suit uniform programs, team apparel and merchandise production. Send your quantity and artwork for a quote on the full run.
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info@firebirdprints.com
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Order Custom Patches
Send your artwork, the quantity, and where the patch is going. We will recommend a type and backing, confirm it on a proof, and produce it.
