A few possibilities. Your patch is made from your own artwork.
Fine detail, woven in.
Custom Woven Patches
Turn your logo into a flat, finely detailed patch. Woven thread holds small text and thin lines that embroidery can’t.
✓ 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 size, shape, border 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 woven patches, woven to your design
Our custom woven patches are made on a loom from thin polyester thread, so they hold fine lettering and thin lines that embroidery can't, in a patch that's thin, flat and flexible. Pick your size, shape and border, upload your art, and we handle the rest. No setup fees, no art fees, and up to 9 thread 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, such as a low-resolution scan or 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 clothing and hat brands, detailed logos and crests, uniforms and workwear, tactical and morale teams, clubs, events, and anyone whose logo has more detail than embroidery can hold.
How to order
- 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. We detect the design itself and trim the blank margin so your patch is sized to your artwork, not the canvas. You'll see exactly what was cropped before you add to cart.
- Set your finished size: up to 7" on the longest side.
- Pick your quantity: minimum 10 pieces. Bulk discounts step down automatically at 25, 50, 100, 200, 500 and 1000 pieces.
- Choose a shape and border: circle, square, rectangle, oval, or a custom shape cut to your artwork, with a merrow or hot-cut edge. Both borders are the same price.
- Select a backing: iron-on / heat seal, sew-on, sticker (peel & stick), or hook & loop (Velcro, +$0.25 per piece). Velcro is the only one that costs extra.
- Add to cart and check out. We'll send a free mockup for your approval. Production doesn't start until you sign off.
Borders, backing & application
- Merrow border. A thick, rolled overlock stitch wrapped around the edge. The classic patch look for circles, squares, ovals and simple shapes. No extra charge.
- Hot-cut border. A clean, heat-sealed edge that follows detailed and custom outlines exactly. No extra charge.
- Iron-on / heat seal. Our most popular backing. Press onto cotton, denim, canvas, twill and cotton-rich blends. Permanent once set.
- Sew-on (no adhesive). A plain back, stitched on by hand or machine. The traditional choice for uniforms and jackets, and the right pick for fabric you don't want to heat.
- Hook & loop (Velcro). +$0.25 per piece. Both hook and loop sides are included, so patches swap on and off bags, gear and hats with loop panels.
- Sticker (peel & stick). Quick, temporary application for events and displays. Not meant for the wash.
Recommended settings for iron-on / heat-seal woven patches:
- Temperature: 300–350°F (150–175°C). Start low and raise the temperature if the patch isn't bonding.
- Press time: 15–20 seconds on a heat press · 30–45 seconds with a household iron, moving slowly
- Pressure: medium to firm, even across the whole patch
- Pre-press: 3–5 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; press from inside the garment for a few seconds to finish
Fabric warning. Nylon, silk, leather garments, waterproof jackets, windbreakers and stretchy technical fabrics react badly to high heat. On those, choose sew-on, or hook & loop and sew the loop side on.
Care instructions
- Wait at least 24 hours before the first wash
- Wash the garment inside out in cold or warm water with a mild detergent
- No bleach or harsh chemicals
- Tumble dry low, or air dry for the longest life
- Never iron directly on the patch. If you iron the garment, turn it inside out or lay a cloth over the patch
Specs
- Material: fine polyester thread woven on a jacquard loom
- Profile: thin, flat and flexible, lighter than embroidery
- Size: any width and height up to 7"
- 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", 4.5", 5", 6", 7"). A 3.1" × 2" patch is priced at the 3.5" rate. The calculator shows you which rate you're in before you add to cart.
- Shapes: circle, square, rectangle, oval, or custom cut to your artwork
- Borders: merrow or hot cut, same price
- Colors: up to 9 thread colors included. Past 9? Add a note and we'll quote the small difference with your proof, before anything is charged.
- Detail: text as small as about 1/8" tall stays legible; solid colors only, no gradients
- Backings: iron-on / heat seal, sew-on, sticker (all no charge), hook & loop Velcro (+$0.25 per piece, both sides included)
- No extra fees: no setup, artwork or revision fee, and no small-order surcharge, unless your file needs significant correction, which we quote with your proof before anything is charged
- Accepted file types: vector preferred (AI, EPS, PDF, SVG); raster accepted (PNG, JPG, PSD) at 300 DPI minimum
- Minimum order: 10 pieces per design
Pricing
Pricing is set 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.
| Size | 10–24 | 25–49 | 50–99 | 100–199 | 200–499 | 500–999 | 1000+ |
|---|---|---|---|---|---|---|---|
| 1.5" | $9.00 | $4.50 | $3.00 | $2.25 | $1.50 | $1.25 | $1.00 |
| 2" | $9.50 | $4.50 | $3.00 | $2.25 | $1.50 | $1.25 | $1.00 |
| 2.5" | $9.75 | $6.00 | $3.75 | $2.75 | $1.75 | $1.50 | $1.25 |
| 3" | $10.25 | $6.75 | $4.00 | $3.00 | $2.00 | $1.75 | $1.50 |
| 3.5" | $10.75 | $6.75 | $5.50 | $3.50 | $2.25 | $2.00 | $1.50 |
| 4" | $11.00 | $10.50 | $6.75 | $4.00 | $3.50 | $2.50 | $2.00 |
| 4.5" | $12.25 | $12.00 | $9.00 | $5.75 | $4.75 | $3.75 | $3.25 |
| 5" | $15.75 | $15.50 | $10.00 | $7.00 | $5.75 | $4.75 | $3.75 |
| 6" | $17.50 | $17.25 | $13.50 | $8.50 | $7.50 | $6.25 | $5.00 |
| 7" | $19.00 | $18.75 | $14.00 | $10.00 | $8.25 | $7.00 | $6.00 |
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. (Velcro backing at $0.25 still applies 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
- 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 woven patch have? Up to 9 thread colors, included in the price with no surcharge. If your artwork needs more, add a note and we'll quote the difference with your proof before anything is charged.
What is the difference between woven and embroidered patches? Embroidered patches are stitched on top of a twill base with thick thread, giving a raised, textured look. Woven patches are made on a loom from much thinner thread, so they're flat and smooth and hold far finer detail. Choose woven when your logo has small text or thin lines.
Should I choose a merrow or hot-cut border? Merrow is the thick rolled stitched edge on classic circle, square and oval patches. Hot cut is a clean heat-sealed edge that follows detailed or custom outlines. Both cost the same, and we'll flag it on your free mockup if your shape suits the other one better.
Which patch backing should I choose? Iron-on for apparel you want it permanent on. Sew-on for uniforms, jackets and anything heat sensitive. Hook and loop Velcro if you want to swap patches between bags, gear or hats. Sticker for quick temporary use. Only hook and loop carries an extra charge.
Is there a minimum order for custom woven 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.
How big can a custom woven patch be? Up to 7 inches on the longest side. Size is priced on the longer side, rounded up to the next standard size.
How small can text be on a woven patch? Lettering down to about 1/8 inch tall stays legible on a woven patch, roughly half the minimum for embroidery. Your free mockup shows exactly how small text will look before production.
Can you match my exact brand colors? Yes. Send your Pantone codes in the notes and we'll match them to the closest thread colors at no extra cost. Your free mockup confirms the colors with you before production starts.
How long do custom woven 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.
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 woven patch guide
Everything worth knowing before you order: how custom woven patches are made, which border and backing to pick, what size to choose, and when woven beats embroidery or PVC.
How custom woven patches are made
A woven patch is made on a loom, not stitched on top of fabric. Thin threads interlace to form the design and the base at the same time, which is why woven holds detail embroidery can’t.
- 1
Your art is set up for the loom
Your design is converted into a weave file that maps every thread color across the patch. Fine lettering and thin lines are planned at thread level.
- 2
Woven on a jacquard loom
Thin polyester threads interlace in a tight pattern to build the whole patch, design and background together. The result is flat, smooth and finely detailed.
- 3
The edge is finished
A merrow border wraps the edge in a thick rolled stitch, or a hot-cut edge is sealed with heat to follow detailed outlines exactly.
- 4
Backed and inspected
The backing you chose is applied, and every patch is checked before it ships.
Woven patches are thinner and lighter than embroidered ones, so they sit flat on hats, sleeves and lightweight fabric without stiffness.
Woven patch borders and backings compared
Both borders are the same price. Only hook & loop backing costs extra.
| Border | What it looks like | Best for | Cost |
|---|---|---|---|
| Merrow | A thick, rolled overlock stitch wrapped around the edge | Circles, squares, ovals and simple shapes. The classic patch look. | Included |
| Hot cut | A clean, heat-sealed edge flush with the patch face | Custom and detailed outlines, sharp corners, die-cut shapes | Included |
| 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 | Uniforms, jackets, workwear, and fabric you don't want to heat. | Included |
| Hook & Loop (Velcro) | Loop side sewn to gear, patch swaps on and off | Tactical gear, packs, morale patches, hats with loop panels. Both sides included. | +$0.25 ea |
| Sticker (Peel & Stick) | Peel and press | Temporary use, events, displays. Not for the wash. | Included |
Heat-sensitive fabric? Nylon, silk, leather garments, waterproof shells and stretchy technical fabric can melt or refuse the adhesive. Choose sew-on or hook & loop instead.
What size should my woven patch be?
Size is priced on the longer of your two dimensions, rounded up to the next standard size. Woven patches go up to 7". Circles below are drawn to scale against each other.
- 1.5"About a poker chipSleeve, collar, small hat side logo
- 2"Short side of a credit cardHat side, polo chest, beanie cuff
- 3"About a coffee mug rimHat front, left chest, morale patch
- 4"About a drink coasterJacket chest, uniform shoulder
- 5"An index card’s long sideBag front, large chest emblem
- 7"About a paperback book’s heightJacket back, large emblem
Fine detail is woven’s strength. Text as small as about 1/8" tall stays legible, roughly half what embroidery needs. If your logo has tiny text or thin lines, woven is usually the right call. Upload your art first and the calculator sets width and height from your file’s own proportions, so nothing gets stretched.
Woven vs embroidered vs PVC patches
Woven isn’t always the right answer. Here’s the honest comparison.
| Feature | Woven | Embroidered | PVC |
|---|---|---|---|
| Look | Flat, smooth thread, finely detailed | Raised thread, classic and textured | Molded rubber, smooth or sculpted |
| Detail | Finest thread detail available. Text down to about 1/8". | Good. Text needs to be at least 1/4" tall. | Very good, limited by mold wall thickness |
| Feel | Thin, light and flexible | Thick and textured | Soft, flexible rubber |
| Weather | Washes well, holds color | Washes well, holds color | Fully waterproof, won't fade |
| Max size | 7" | 14" | 4" |
| Choose it when | Your logo has small text or fine lines, or you want a low-profile patch | You want the traditional textured patch look | Gear lives outdoors, or you want a modern rubber look |
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 woven patches
Clothing & hat brands
Clean, detailed brand patches for hats, hoodies and denim, 1.5" to 3".
Detailed logos
Crests, maps, fine script and small lettering that would fill in as embroidery.
Uniforms & workwear
Company and department patches that stay flat and light on shirts and jackets.
Tactical & morale patches
Hook & loop backing, 2" to 3.5", with detail that reads from across the room.
Teams, clubs & events
Commemorative and achievement patches. The minimum is only 10 pieces.
Resellers & decorators
Volume pricing steps down to 1000+ pieces. Email support@atlantavinylstore.com for recurring-order and wholesale terms.