A few possibilities. Your patch is made from your own artwork.
Small detail. Big identity.
Custom PVC Patches
Turn your logo into something you can feel. Durable molded patches, made your way.
✓ 10-piece minimum ✓ Free digital mockup ✓ Approve before production
From idea to everyday
Your design.
We take it from here.
Make it yours
Choose your style, size and backing. Send us your artwork.
See it before anything is made
After 1–2 business days of processing, we send a free mockup for approval.
Bring your brand to life
Production takes about 10–14 business days after proof approval.
Custom PVC patches, molded to your design
Our custom PVC patches are molded — not printed — in soft, flexible rubber, with crisp molded lines separating every color. They're 100% waterproof and built to survive the gear they ride on: they won't fray, unravel, or fade like a stitched patch, indoors or out. Choose 2D for a smooth flat face or 3D for sculpted, raised layers. Pick your style and size, upload your art, and we handle the rest. No setup fees, no mold fees, no art fees, and up to 9 colors included — the price you see is the price.* Minimum 10 pieces.
*We prep your artwork free. On the rare file that needs significant correction to be production-ready — a low-resolution scan, artwork that has to be redrawn — we will quote that small charge along with your proof. You approve it before anything is charged, and you can walk away at that point.
Built for tactical and morale teams, outdoor and workwear brands, hat and apparel lines, motorcycle and car clubs, gyms, breweries, schools, and anyone who wants a logo that holds up and stands out.
2D or 3D: which style do you want?
Both are molded from the same soft PVC rubber and both are fully waterproof. The difference is depth, and it changes which artwork reproduces best.
- 2D — Standard. Every color sits at the same level, separated by clean raised lines, giving a smooth flat face. Fine lines and small text hold up better because nothing competes for vertical space. This is the standard style and what most first-time buyers choose. Best for logos with text, tight detail, brand labels, hat patches, anything that has to read clearly at a small size.
- 3D — Raised Layers. The artwork is molded in raised layers so the design has real height, shadow and contour. It catches light and reads as a sculpted emblem rather than a flat badge. Detail has to be a little bolder, since very fine elements get lost between the levels. Best for mascots, crests, animals, shields and unit emblems. 3D is also the only style we offer glow-in-the-dark on.
3D runs a little more per piece than 2D. Switch between them in the calculator and the price updates instantly, so you can compare before you decide. Not sure which suits your artwork? Send it over and we'll tell you honestly, and your free mockup shows you before anything is molded.
How to order
- Pick your style — 2D or 3D. The price table updates as you switch.
- Upload your artwork. We read its proportions automatically and set your width and height to match, so your patch comes out the shape you designed — not stretched. Adjust either box and the other follows.
- Empty space is cropped automatically. Logos are often saved on a much larger canvas with blank space around them. We detect the design itself, trim the margin, and produce from the cropped version — otherwise your patch would be molded to the shape of the empty canvas rather than your artwork. You'll see exactly what was cropped before you add to cart. If the crop is not what you intended, remove the file and upload a revised version before ordering. The original raster file is not attached separately.
- Set your finished size — anything up to 4" on the longest side, which is the largest PVC mold we run. Any outline you like within that: circles, shields, banners, or a fully custom shape.
- Pick your quantity — minimum 10 pieces. Bulk discounts step down automatically at 25, 50, 100, 200, 500, and 1000 pieces.
- Select a backing — iron-on / heat seal, sticker (peel & stick), sew-on (plain back), or hook & loop (Velcro, +$0.25 per piece). Velcro is the only one that costs extra.
- File types. Vector is preferred — AI, EPS, or PDF. Raster is accepted (PNG, JPG, PSD) at 300 DPI minimum. Very fine detail and small text don't hold up in a mold, so simpler, bolder art reproduces best. Our design team can help optimize yours. (PNG, JPG and SVG can preview on screen. AI, EPS, PDF, PSD and TIFF require manually entered dimensions. Confirm the finished size before ordering.)
- Add to cart and check out. We'll send a free mockup for your approval before the mold is cut — production doesn't start until you sign off.
Application & backing
Backings are the same on both styles, and only Velcro costs extra. How you apply the patch depends on which you choose:
- Iron-on / Heat Seal — our most popular. Press onto cotton, denim, canvas, twill, and cotton-rich blends with a household iron or heat press. Permanent once set.
- Sticker (Peel & Stick) — quick stick for smooth surfaces, displays, and hard cases. Not meant for the wash.
- Hook & Loop (Velcro) — +$0.25 per piece. Both hook and loop sides are included, so you can add the loop side to bags, plate carriers, and jackets and swap patches on and off.
- Sew-On (No Adhesive) — a plain back with no adhesive, stitched on by hand or machine. The traditional choice for club vests, uniforms, and workwear, and the right pick for any fabric you don't want to put heat near. No extra charge.
Recommended settings for iron-on / heat-seal PVC patches:
- Temperature: 300–350°F (150–175°C). Start at 300°F. Heat press readouts are often off by 20–30°F — if the patch isn't bonding, raise the temperature before you extend the press time.
- Press time: 15–20 seconds on a heat press · 20–25 seconds with a regular iron
- Pressure: medium to firm, even across the whole patch
- Pre-press: 2–3 seconds on the garment first, to drive out moisture and wrinkles
- Cover: parchment paper or a Teflon sheet over the patch
- Cooling: let the patch cool completely before you check the bond
Exact settings vary with the fabric, the garment, your press, and the adhesive. On synthetic or heat-sensitive fabrics, start at the low end of the range and test first.
Fabric warning. Nylon, silk, leather, polyester, waterproof jackets, windbreakers, and stretchy technical fabrics react badly to high heat — they can melt, wrinkle, or repel the adhesive. Cotton, denim, canvas, twill, and heavy cotton blends are the reliable choices for heat application. On anything heat-sensitive, choose sew-on and stitch it straight on, or hook & loop and sew the loop side on.
Care instructions
- Let the patch cool and fully bond before handling
- Wait at least 24 hours before the first wash
- Wash the garment inside out
- Use cold or warm water and a mild detergent
- No bleach or harsh chemicals
- Do not dry clean
- Tumble dry on low to medium heat — air drying is better
- Never put an iron directly on the patch. If you iron the garment, turn it inside out or lay a cloth over the patch
- Avoid prolonged or excessive direct heat on the patch
Specs
- Material: soft, flexible PVC rubber — 100% waterproof and weather-resistant
- Styles: 2D (standard) is a smooth, flat face with each color molded into its own recessed section, separated by clean raised lines. 3D is molded in raised layers for real height, shadow and contour. Both are cut to any outline and both are fully waterproof.
- Size: any width and height up to 4" on either side, on both styles. 4" is the maximum size a PVC mold runs — we don't make them larger.
- How size is priced: by the longer of your two dimensions, rounded up to the next standard size (1.5", 2", 2.5", 3", 3.5", 4"). A 3.1" × 0.8" patch is priced at the 3.5" rate. The calculator shows you which rate you're in before you add to cart.
- Shape & edge: molded and cut to any outline — circles, shields, banners, or fully custom. The edge comes out of the mold clean and sealed, so there's no stitched border to choose and nothing to fray.
- Colors: up to 9 colors included at no extra charge on both styles — more than almost any patch design needs. Past 9? Add a note and we'll quote the small difference with your proof, before anything is charged.
- Pantone: send your PMS references and we'll match them as closely as the available PVC colors allow. Molded rubber can't hit every Pantone exactly, so we'll confirm on your mockup before production.
- Backings: iron-on / heat seal (no charge), sticker / peel & stick (no charge), sew-on / plain back (no charge), hook & loop Velcro (+$0.25 per piece — both sides included). Same on 2D and 3D.
- Glow in the dark: available on 3D only, +$0.50 per piece. It charges in daylight and glows in the dark. Not available on 2D, and reflective and metallic finishes are not offered on PVC at all.
- No extra fees: no mold or die fee, no artwork or vector cleanup fee, no revision fee, and no small-order surcharge — unless your file needs significant correction to be production-ready, in which case we quote that with your proof, before anything is charged
- Accepted file types: vector preferred (AI, EPS, PDF); raster accepted (PNG, JPG, PSD) at 300 DPI minimum
- Auto-cropping: blank space around your design is trimmed automatically so the patch matches your artwork, not your canvas. Vector files are not altered. Review the crop before ordering; upload a revised file if you need a different crop.
- Minimum order: 10 pieces per design, either style
Pricing
Pricing is set by your style, by the longer of your two dimensions rounded up to the next standard size, and by quantity. The bigger your run, the lower your per-piece price. All prices are per patch in USD.
2D PVC patches (standard)
| Quantity | 1.5" | 2" | 2.5" | 3" | 3.5" | 4" |
|---|---|---|---|---|---|---|
| 10–24 | $10.00 | $10.50 | $11.25 | $12.00 | $13.50 | $15.00 |
| 25–49 | $8.75 | $10.00 | $11.00 | $11.75 | $13.25 | $14.75 |
| 50–99 | $5.75 | $6.25 | $7.00 | $7.75 | $8.50 | $9.50 |
| 100–199 | $4.00 | $4.75 | $5.25 | $6.00 | $6.75 | $7.75 |
| 200–499 | $2.50 | $3.00 | $3.50 | $4.00 | $4.50 | $5.25 |
| 500–999 | $1.75 | $2.00 | $2.50 | $2.75 | $3.25 | $3.50 |
| 1000+ | $1.50 | $1.75 | $2.00 | $2.25 | $2.50 | $3.00 |
3D PVC patches (raised layers)
| Quantity | 1.5" | 2" | 2.5" | 3" | 3.5" | 4" |
|---|---|---|---|---|---|---|
| 10–24 | $12.50 | $13.00 | $13.50 | $14.00 | $15.75 | $17.25 |
| 25–49 | $10.25 | $11.50 | $12.75 | $13.75 | $15.25 | $17.00 |
| 50–99 | $6.75 | $7.25 | $8.25 | $9.00 | $10.00 | $11.00 |
| 100–199 | $4.75 | $5.50 | $6.25 | $7.00 | $8.00 | $9.00 |
| 200–499 | $3.25 | $4.25 | $4.75 | $5.25 | $5.75 | $6.25 |
| 500–999 | $2.75 | $3.75 | $4.25 | $4.75 | $5.00 | $5.50 |
| 1000+ | $2.50 | $3.00 | $3.50 | $4.00 | $4.50 | $5.00 |
Best-price guarantee. You will never pay more than you would by ordering a larger quantity. If your order sits just under a price break, the calculator automatically charges you the lower tier's total — and tells you how many extra patches you can add at no additional patch cost. No need to do the math yourself. (Per-piece options, Velcro backing at $0.25 and 3D glow at $0.50, still apply to every patch made.)
Our guarantee
- 100% satisfaction guarantee on every order
- Free design revisions until you're happy — production doesn't start until you approve the proof
- Quality control inspection on every patch before it ships
- Free reprints for any manufacturing error
- 30 days to report an order issue — email support@atlantavinylstore.com with photos, or call (404) 720-5656, and we'll make it right
One note: because every patch is made to your artwork, changes requested after you approve the proof may carry additional cost. Please review your mockup carefully.
Production & turnaround
- Order processing: 1–2 business days
- Free mockup: sent for your approval before production starts
- Production: about 10–14 business days after you approve the mockup, on both styles
- Reorders: have a past order number? Drop it in the “Notes for Production” field and we'll match your previous specs exactly.
FAQ
How many colors can my patch have? Up to 9, included in the price with no surcharge. Most patch designs use three to five, so almost nothing runs past it. If your artwork does, add a note and we'll quote the difference with your proof before anything is charged.
What is the difference between 2D and 3D PVC patches? On a 2D PVC patch every color sits at the same level, separated by clean molded lines, giving a smooth flat face that holds fine detail and small text well. On a 3D PVC patch the artwork is molded in raised layers so it has real height and shadow. 2D is the standard and more popular choice. 3D suits emblems, mascots and logos meant to pop off the surface, and it is the only PVC style offered with glow in the dark.
Are PVC patches really waterproof and outdoor safe? Yes. PVC rubber does not absorb water and will not fade in sunlight, so the patches hold up on packs, jackets, hats and gear in any weather. There are no threads to fray or unravel.
Which patch backing should I choose? Iron-on or heat seal for apparel you want it permanent on. Sew-on for club vests, uniforms and anything heat sensitive you would rather stitch. Hook and loop Velcro if you want to swap patches between bags or kit. Sticker for quick temporary display on hard surfaces. Only hook and loop carries an extra charge.
How are custom PVC patches made? PVC patches are molded rather than printed or embroidered. Your artwork is cut into a metal mold with one recess per color, soft PVC is laid into each recess by hand, then heat and pressure cure it into a single flexible piece with a sealed edge. The patch is then trimmed to your outline and the backing is applied.
What is the largest PVC patch you can make? 4 inches on the longest side. That is the largest PVC mold available, not a pricing limit, so it cannot be stretched. For patches larger than 4 inches, embroidered and woven patches go well past that size.
Is there a minimum order for custom PVC patches? The minimum is 10 pieces per design. Volume pricing steps down automatically at 25, 50, 100, 200, 500 and 1000 pieces, and the calculator never charges more than the next tier's total would cost.
Can you match my exact brand colors? Yes. Send your Pantone PMS codes in the notes and we will color match at no extra cost. Molded rubber cannot hit every Pantone exactly, so the free mockup confirms the colors with you before production starts.
How long do custom PVC patches take? Order processing takes 1 to 2 business days, then a free mockup is sent for your approval. Production runs about 10 to 14 business days after you approve the mockup. Nothing goes into production until you sign off on the proof.
Do you offer wholesale or recurring orders? Yes. Email support@atlantavinylstore.com and we'll set you up with priority production and volume pricing.
Related guides
The PVC patch guide
Everything worth knowing before you order: how custom PVC patches are made, which backing to pick, what size to choose, and when PVC beats embroidery.
How custom PVC patches are made
PVC patches aren't printed and aren't embroidered. They're molded, which is why they behave so differently from a stitched patch.
- 1
Your artwork becomes a mold
The design is cut into a metal mold with one recess per color. The mold has to physically hold a wall between colors, which is why hairlines and tiny text don't survive.
- 2
Colors are filled by hand
Soft PVC in each color is laid into its own recess. Every color is a separate physical section, not a dye or a thread, so nothing bleeds or runs.
- 3
Heat and pressure cure it
The filled mold is cured so the colors fuse into one flexible piece of rubber with a clean, sealed edge.
- 4
Trimmed and backed
The patch is cut to your outline and the backing you chose is applied. Then it's inspected before it ships.
Because the color is the material itself rather than a layer sitting on top, a PVC patch won't fade in sunlight, won't absorb water, and has no threads to fray. That's why PVC took over tactical and outdoor gear.
PVC patch backing options compared
Same four backings on 2D and 3D. Only hook & loop costs extra.
| Backing | How it attaches | Best for | Cost |
|---|---|---|---|
| Iron-On / Heat Seal | Heat press or household iron | Cotton, denim, canvas, twill. Permanent once set. | Included |
| Sew-On (No Adhesive) | Stitched by hand or machine | Club vests, uniforms, workwear, and fabric you don't want to heat. | Included |
| Hook & Loop (Velcro) | Loop side sewn to gear, patch swaps on and off | Plate carriers, packs, jackets, morale patch rotations. Both sides included. | +$0.25 ea |
| Sticker (Peel & Stick) | Peel and press | Hard smooth surfaces, cases, displays. Not for the wash. | Included |
Heat-sensitive fabric? Nylon, silk, leather, waterproof shells, windbreakers and stretchy technical fabric can melt, wrinkle or refuse the adhesive. Choose sew-on or hook & loop instead. It's the difference between a patch that lasts and a ruined jacket.
What size should my PVC patch be?
Size is priced on the longer of your two dimensions, rounded up to the next standard size. Circles below are drawn to scale against each other.
- 1.5"About a golf ballHat side panel, sleeve, polo chest, bag label
- 2"Short side of a credit cardHat front, left chest, beanie cuff
- 2.5"About a tennis ballStandard morale patch, work shirt chest
- 3"About a coffee mug rimClassic morale patch, plate carrier front, jacket chest
- 3.5"Long side of a business cardBack of a cap, larger chest emblem, pack panel
- 4"About a drink coasterLargest PVC mold. Jacket accent, large gear panel.
4" is a hard ceiling on PVC. It's the largest mold available, not a pricing tier we can stretch. Need bigger? Embroidered and woven patches go well past 4". Upload your art first and the calculator sets width and height from your file's own proportions, so nothing gets stretched.
PVC vs embroidered vs woven patches
PVC isn't always the right answer. Here's the honest comparison.
| Feature | PVC | Embroidered | Woven |
|---|---|---|---|
| Look | Molded rubber, smooth or sculpted, modern | Raised thread, classic and textured | Flat thread, finer than embroidery |
| Detail | Very good, limited by mold wall thickness | Coarsest. Small text struggles. | Finest thread detail available |
| Weather | Fully waterproof, won't fade | Absorbs water, can fade | Absorbs water |
| Feel | Soft, flexible rubber | Thick and textured | Thin and flat |
| Max size | 4" | Well past 4" | Well past 4" |
| Choose it when | Gear lives outdoors, or you want a modern look that survives weather | You want a traditional, premium, textured badge | You need fine detail in a flat, low-profile patch |
Not sure which suits your artwork? Send it to support@atlantavinylstore.com and we'll tell you which one it will actually look good as.
Who orders custom PVC patches
Tactical & morale patches
Hook & loop, 2" to 3.5", built to live on a plate carrier in the rain. The single biggest use for PVC.
Motorcycle & car clubs
Sew-on for vests and jackets. PVC holds a hard-edged logo better than embroidery and survives weather that destroys thread.
Outdoor & workwear brands
Brand labels on packs, shells and hi-vis. Waterproof, won't fade, no fraying edge after a season of abuse.
Hat & apparel lines
1.5" to 2.5" front or side patches. A molded edge gives a small logo a sharpness stitching can't match at that scale.
Gyms, breweries & schools
Merch, team and club identifiers, event runs. The minimum is only 10 pieces, so a small run is a real option.
Resellers & decorators
Volume pricing steps down to 1000+ pieces. Email support@atlantavinylstore.com for recurring-order and wholesale terms.