Types of Patches: Embroidered, PVC, Woven and More
The main types of patches are embroidered, PVC or rubber, woven, printed, leather and chenille. They differ in how the design is made — stitched in thread, moulded in soft plastic, woven as fabric, printed on a surface — and that decides how much detail you get, how it feels, and what it suits. This guide explains each type, then the two choices people actually get wrong: backing and border.
Quick Answer
- Most popular
- Embroidered — the classic stitched patch
- Finest detail
- PVC, or woven for thread-based detail
- Toughest outdoors
- PVC — waterproof, cannot fray
- Full-colour artwork
- Printed, or UV-printed PVC
- Available at MZIHO
- Embroidered and PVC, from 10 pieces
- Decided separately
- Backing, border and shape
Embroidered patches
Thread stitched onto a twill backing. The oldest and still the most common type: it is what most people picture when they hear "patch", and it is what uniforms, scout sashes, club jackets and varsity wear have used for a century.
Thread gives texture you can feel and a slight sheen that changes as the light moves. What it cannot do is blend — every colour is a separate area of stitching, so gradients and photographs have to be redrawn as flat shapes. Fine detail is limited by how thin a line of stitches can be, which in practice means text under about a quarter inch tall starts to blur.
One thing unique to embroidery is thread coverage: how much of the twill you actually stitch over. At 50% the background fabric shows around the design, which suits a logo on a coloured base. At 100% the whole surface is stitched and the twill disappears entirely.
Embroidery also carries upgrades no other type offers: metallic gold and silver thread, reflective thread, glow in the dark and fluorescent. See custom embroidered patches.
PVC and rubber patches
Moulded from soft, flexible PVC in a custom tool rather than stitched. The colour is part of the material, so it cannot fray, peel or fade, and the patch is waterproof and wipes clean.
The reason PVC has taken over tactical and outdoor use is detail. A mould holds much finer lines than a needle can stitch, so small lettering, thin outlines and busy unit crests reproduce properly. It also gives a flat, matte, modern look that suits subdued designs.
PVC can be made flat (2D, colours layered at a couple of heights) or sculpted (3D, surfaces curved and shaped). It adds its own effects too: glow in the dark, glitter through the material, transparent colour and full-colour UV printing. See custom PVC patches.
The other types you will come across
These are worth understanding when you are comparing quotes, even though each suits a narrower set of jobs:
- Woven patches. Made on a loom with much thinner thread than embroidery, so they hold far more detail and sit flat with no texture. Good for intricate crests and small text; they lack the raised, tactile quality that makes embroidery feel substantial.
- Printed patches. Artwork printed onto fabric and cut to shape. Unlimited colours and photographic detail, and the cheapest way to reproduce complex artwork — but the print sits on the surface and wears before the fabric does.
- Leather patches. Debossed or laser-engraved leather, usually a single tone. Understated and durable, common on hats and denim, but limited to one colour of impression.
- Chenille patches. Thick, fuzzy yarn — the classic varsity letter. Bold and tactile at a distance, and incapable of any fine detail at all.
- Sublimated patches. A print process that dyes the fibres rather than coating them, so the colour does not sit on top. Full colour, flat finish, no texture.
Comparing the main types
| Type | Detail | Feel | Colour | Best for |
|---|---|---|---|---|
| Embroidered | Moderate | Raised, textured | Solid thread colours | Uniforms, clubs, scouts, varsity |
| PVC | High | Smooth, flexible | Solid moulded, or UV printed | Tactical, outdoor, detailed crests |
| Woven | High | Flat, fabric | Solid thread colours | Intricate crests, small text |
| Printed | Photographic | Flat, printed | Unlimited | Complex artwork on a budget |
| Leather | Low | Firm, natural | One tone | Hats, denim, heritage branding |
| Chenille | Very low | Thick, fuzzy | A few yarn colours | Letters and numbers |
Backing is a separate choice
People often talk about "velcro patches" or "iron-on patches" as if those were types. They are not — they are backings, and any patch type can have any of them. Four options:
| Backing | Use it when |
|---|---|
| Sew-on | It should stay put for good. The toughest option, and the only sensible one for knees, elbows and gear |
| Iron-on | Cotton, denim or canvas, and you want it on in two minutes — see how to iron on a patch |
| 3M self-adhesive | Hard surfaces and cases, or short-term use |
| Double velcro | You want to swap patches — the standard for morale patches |
Border and shape, the two details that change the look
On an embroidered patch the border is a real decision. A merrow border is thread rolled around the edge — the raised rope-like rim on a classic round patch. A laser or hot cut edge is trimmed to the outline, which is what lets a patch follow a complicated shape rather than sitting inside a circle.
Shape follows from that. There are 16 standard shapes to choose from — circle, square, oval, rectangle, diamond, four shields, hexagon, rocker, banner, fan — plus a custom die cut to your own outline. A merrow border only works on simple shapes; anything intricate needs the cut edge.
Which should you choose?
Choose embroidered if…
- You want the traditional stitched look and texture
- The design is bold with a handful of colours
- It sits alongside existing embroidered insignia
- You want metallic, reflective or glow thread
Choose PVC if…
- The artwork has fine lines or small text
- It will live outdoors or on gear
- You want a flat, subdued, modern finish
- You want glow, glitter or a transparent background
- Looked at your artwork: bold shapes, or fine detail?
- Decided where it lives: clothing, uniform, or gear
- Chosen a backing to match that, not by habit
- Picked a border — merrow for simple shapes, cut edge for outlines
- Checked the smallest text at actual size
- Counted your colours, since price bands change with them
Frequently asked questions
What is the most common type of patch?
Embroidered. It is what uniforms, clubs, scouts and varsity jackets have used for decades, and it is still the default unless the artwork or the environment pushes you elsewhere.
What is the difference between embroidered and woven patches?
Both are made from thread, but weaving uses much finer thread on a loom, so a woven patch holds more detail and sits completely flat. An embroidered patch is thicker and textured. Choose woven for intricate crests, embroidered for the raised, traditional feel.
Are PVC and rubber patches the same thing?
Yes. In custom patches the two words describe the same product — a patch moulded from soft, flexible PVC. "Rubber" describes how it feels rather than what it is made of.
Which type of patch is most durable?
PVC. The colour is moulded into the material, so there is nothing to fray, peel or fade, and it is waterproof. Embroidered patches are also hard-wearing; their weak point is the edge, which is why the border choice matters.
Is velcro a type of patch?
No, it is a backing. Any patch type can be made with velcro, iron-on, 3M adhesive or a plain sew-on back, and that choice is made separately from the patch type itself.
What is the minimum order?
Ten pieces per design, for both embroidered and PVC. Quantity tiers run 10, 25, 50, 100, 250, 500 and 1,000, and the per-piece price falls at each step.
Working out how your design should be made? How custom patches are made walks through the process, or browse all custom patches.
Found your type?
Choose your size, quantity and options, see your price online and upload your artwork. From 10 pieces per design, with a free digital proof before production.
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