Custom Woven & Embroidered Patches – Full-Service Solutions from The Foundry Print Shop

At The Foundry Print Shop, we offer a complete custom patch program—covering everything from design and production to application. Whether you’re outfitting headwear, uniforms, or promotional pieces, we’ve got you covered with professional-grade patches tailored to your exact needs.

Types of Custom Patches

There are several ways to create a custom patch, each with its own look and feel:

• Embroidered Patches: Classic and textured, ideal for bold designs.

• Woven Patches: Great for detail and fine lines.

• Printed, PVC, and Sublimated Patches: Perfect for vibrant colors and photorealistic artwork.

We help you choose the best construction method by considering the artwork, garment type, and usage. For example, patches on knitwear should be lightweight and flexible, while hats have size limitations. That’s where our experience makes a difference.

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Minimums for Custom Patch Orders

Patch pricing depends on size, construction type, and quantity. Since most of the cost lies in setup and equipment, ordering more significantly reduces your cost per unit. For example:

• Minimum Order: 50 patches

• Recommended for Savings: 100+ patches (up to 40% savings)

If you’re ordering 50 custom hats, it often makes sense to order extra patches for future use—it saves money and speeds up turnaround for reorders.

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Turnaround Times

Most custom patches are produced in-house with a standard 2-week turnaround. For certain patch styles or specialty trims, we may outsource to a dedicated factory to ensure the best price and quality. In those cases, allow up to 4 weeks total.

To get the best results and widest range of options, we recommend starting your patch project at least 30 days in advance.

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Patch Backing Options

Patch backing refers to how the patch attaches to a garment. Here are the most common options:

• Heatseal (Iron-On): Great for DIY application. Best when also sewn for durability.

• Sew-On: The most permanent solution, ideal for regular wear or wash.

• Hook & Loop (Velcro): Perfect for removable or interchangeable patches.

• Peel & Stick: Good for temporary placement or event giveaways.

We always recommend sewing for a long-lasting bond—especially on gear that gets heavy use.

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Patch Border Styles

There are two main border types:

• Merrow Border: The thick, raised edge seen on most classic patches. Works best on simple shapes like circles or rectangles.

• Satin Stitch Border: Used on complex shapes. It mimics the merrow look but is cut with a hot knife or laser to prevent fraying.

We’ll help you pick the best option for your patch shape and design.

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Application to Garments

Once your patches are made, it’s time to apply them. We offer both:

• Professional Sewing Services: With a full range of specialty equipment, we can apply patches to hats, jackets, bags—you name it.

• Heat Press Application: For iron-on patches, we use industrial heat presses that ensure a perfect seal with the right temperature, pressure, and timing.

Want to try it yourself? Here’s a helpful guide on how to sew on a patch from Instructables.

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Let’s Talk Patches

If you have a patch project in mind, let us help you bring it to life. Whether it’s a small run for your crew or a large-scale production for your brand, we’ll guide you through the best construction methods, pricing strategies, and application options.

Reach out anytime—your custom patch experts at The Foundry are here to help.

We offer full-service custom patch application with seamless, start-to-finish project management. From design to final placement, The Foundry ensures every patch project is handled with precision, care, and our signature world-class service. Let us be your go-to partner for all things patches.

Custom Woven Labels

Custom Embroidered Patches