Patch Type Pros and Cons

Custom patches can be useful tools, communicating important information, identifying team or squad members, showing membership or marketing a brand or product. They can add style and fun to fashion as well. But how do you choose among the multiple patch types? Which one is best for your intended use?

Different patch styles and materials fit different purposes. For example, if you need a rugged outdoor tactical patch, you’ll need a different type than a simple business uniform name patch.

We’re here to help you find the best patch type for your needs. Let’s take a look at the types of patches available, their pros and cons, and how to find the right one for you.

Four Basic Patch Types

We’ll be comparing the four most common patch types: Embroidered, Woven, Printed and PVC. They offer a range of detail levels, attachment methods, price and durability. Each has its own unique strengths and weaknesses, and what works well for one customer might not be the right choice for another.

Embroidered Patches

This is the most popular, and often the least expensive, patch type. Your design is created by machine-stitching thread onto a twill backing. This is the classic patch style, the one most people think of when they hear the word patch. The raised stitching creates texture that you can see and feel.

Embroidered patches are best with moderate detail. The thickness of the thread limits the amount of detail you can include and still have a legible, good-looking design. If your design requires finer detail, or text in a small font, a different patch type will be a better choice.

This patch style most commonly features a merrowed (sewn) border. This raised border provides additional definition to the patch, giving it a distinctive raised appearance from the material it’s attached to. They also can be ordered with a heat cut border for a clean, modern look.

Thread choices will determine colors for embroidered patches. Most providers offer 5 to 7 colors free on embroidered designs, with additional colors available for an extra charge.

Embroidered patches give you the most flexibility for attachment styles of any patch types, including iron-on, sew-on or hook-and-loop fastener (Velcro®). They’re ideal for uniform patches, caps, jackets, and logos where texture is desired.

This patch type typically offers very good durability, and will stand up well to outdoor use, general wear and regular washing. It’s a versatile choice for almost any application if cost is an issue.

Woven Patches

Woven patches are similar to embroidered ones, but are made with a thinner thread. This allows for much finer art and text and greater color detail. You can use smaller text and still maintain legibility on the patch. The tradeoff is that they feature less texture than the embroidered type. It’s a flatter look, with less visual “pop” than embroidery.

Color options are typically the same as for embroidered patches – 5 to 7 colors free (depending on the supplier), with additional colors available at extra cost.

Durability of woven patches is generally good, but slightly less so than embroidery due to the thinner thread being used. Like embroidered patches, woven ones also allow great flexibility in attachment styles. While they typically feature a merrowed border, they can have a heat-cut border as well.

Printed Patches

Printed patches are perfect for high-detail, photorealistic patch designs. If you want extreme detail, gradients and shading, and infinite color combinations, printed patches are the answer.

Unlike with embroidered or woven patches, the design is imprinted directly onto the patch fabric. Any kind of artwork that can be printed can be reproduced. This style is ideal for event patches. This style is generally more expensive than embroidered or woven patches.

Printed patches are typically sewn on or attached with adhesive. They might or might not be compatible with iron-on backing, depending on the material. These patches will feature a heat-cut border with clean edges.

Printed patches are reasonably durable, but can be subject to cracking or fading over time, especially with extensive outdoor exposure.

PVC Patches

For rugged durability, you can’t beat PVC patches. These patches are made of polyvinyl chloride, a soft, rubberlike plastic that can stand up to heavy outdoor wear. Their imprinted designs allow for fine detail and multiple colors, although they generally allow less detail than printed patches.

Where PVC patches really shine is in their outstanding resistance to weather, moisture, and abrasion. Those qualities make them popular for rugged gear, including military and tactical gear, including outerwear, bags, backpacks and shoes. These patches will always include a heat-cut border.

PVC patches are the most expensive patch style, but their excellent durability and wear factors make them the right choice for many applications. Unlike the other patch types, you’re more limited in your choice of attachment methods with PVC.  Iron-on application is not possible with these patches, because the heat would damage the patch material.

Pros and Cons of Each Patch Type

Here’s a basic list of the pros and cons of each path type:

Embroidered

Pro:

• Texture
• Traditional look
• Good durability

Con:

• Can be bulky
• Small detail may get lost
• Not ideal for photo/gradient designs

Woven

Pro:

• Greater detail possible especially with text
• Smooth appearance
• Better for small text or logos

Con:

• Flatter look -- less visual “pop” than embroidered (especially with heat-cut border)
• Less tactile feel than embroidered
• Edges and backing might be less rugged

Printed

Pros:

• Infinite color variation
• Gradients possible
• Photo-realistic

Cons:

• Less texture
• Prints may fade or crack
• Can be less durable outdoors or in other rugged conditions

PVC

Pros:

• Very durable
• Water-resistant, ideal for outdoors or rugged use
• Easy to clean

Cons:

• Heavier than other types
• Iron-on attachment not possible
• Slightly less detail than printed

Which Patch Type is Right for You?

Choosing the right patch type might seem like a daunting task, but it doesn’t have to be. At Patches4Less.com, we have 20 years’ experience helping customers create the perfect patches for their needs. We’ll work with you every step of the way to make sure you get exactly the patches that are right for you.

Want to find out more? Call us toll free at (866) 847-2844, or email us. If you already have a design in mind for your patches, fill out our no-obligation free quote form and we’ll send you a free digital proof of your design. We’re here to serve all your custom patch needs!