When you’re designing custom patches for your business, team, or brand, choosing the right patch style is just as important as the artwork itself.
We’re always happy to offer professional recommendations based on your unique design and application. However, many customers ask for more details on each patch type. Understanding the strengths of each patch type is incredibly helpful during the creative process. When designers start with the final patch style in mind, they can tailor their artwork from the beginning to ensure a flawless final product.
Patch Types:
Embroidered Patches
Embroidered patches are the “original” or “classic” patch. Embroidery uses thick rayon or polyester threads and a specialized machine to sew your design onto a fabric background, creating a slightly raised, high-texture look and feel. (We avoid cotton threads because they break easily during production and break down much quicker over time).
Because of the thickness of the thread and the physical needlework required, certain design limitations apply. Lines should be thick and bold, and text should be a block font (or a font with very thick serifs) at a minimum height of 0.2” tall. Small details may lose a bit of sharpness or end up with slightly fuzzy edges.
Additionally, while color gradients are technically possible with embroidery, we generally advise against them. Blending thread colors to create a smooth fade is incredibly difficult, and the final result rarely matches the clean look customers expect.
Durability: Embroidery thread dye is naturally highly resistant to UV rays, so it strongly resists fading in direct sunlight. (Note: While highly UV-resistant, any textile will eventually show subtle fading if left in harsh, outdoor elements for years). Because it is our thickest option, it is also highly resistant to tearing and abrasion.
Best For:
- Bold lines and solid colors
- Block fonts
- Designs requiring up to 15 solid colors
- Workwear, heavy uniforms, and hats
Do Not Use For:
- Gradients (fades from one color to another)
- Small, intricate details and thin lines
- Delicate script or fancy fonts
- Outlined text (unless both the lettering and the outline are exceptionally large and bold)
Woven Patches
Woven patches were the next development in patch history. Instead of stitching a design on top of a heavy background fabric, woven patches are created by weaving thin, fine threads together to form both the background and the design simultaneously.
Because the threads are much thinner, woven patches excel at keeping small details and thin outlines looking incredibly sharp. However, because the threads run in a precise weave, exceptionally fine curves might reveal the subtle “grid” of the fabric up close, giving them a slightly digitized or pixelated appearance rather than a perfectly smooth line.
From a distance, a woven patch delivers the clean visual impact of embroidery, but up close, it offers a distinctively smooth, flat, low-profile feel. They are also lighter and more flexible, making them suitable to attach to performance apparel.
Durability: Woven patches use similar high-quality, fade-resistant threads as embroidery. However, because the threads are much thinner and more delicate, they stand up just a little bit less to rugged, high-friction use and heavy washing compared to their thick, embroidered counterparts.
Best For:
- Small, intricate details and fine lines
- Solid colors
- Fancy, seriffed, and detailed fonts
- Designs requiring up to 15 colors
- Lightweight apparel and sportswear
Do Not Use For:
- A classic, textured look and feel
- Gradients
Sublimated Patches
Sublimated patches are the most recent innovation in patch technology. Instead of constructing an image out of thread, sublimation uses heat and pressure to bond digital ink directly to the molecules of a smooth, synthetic (usually polyester) fabric.
Printing the design allows for total artistic freedom and absolute control over your graphics. You can use smooth gradients, tiny details, and thin, decorative fonts. Sublimation can replicate hand drawings, watercolor illustrations, and photographs.
Durability: Because the ink is infused into the top layer of the fabric rather than built from thick structural threads, sublimated patches are best suited for casual wear rather than heavy-duty work uniforms. Rest assured, your design won’t wash out in the laundry, but over extended periods of heavy use or exposure to direct sunlight, a printed patch will naturally show its age sooner than a stitched one.
Best For:
- Small, intricate details and razor-thin lines
- Fancy, complex, or heavily outlined fonts
- Smooth gradients and color transitions
- Replicating photos and detailed illustrations
- Unlimited colors
Do Not Use For:
- A classic, textured “raised” feel
- Heavy-duty workwear or high-exposure outdoor gear
So which patch type do I choose?
Every patch style comes with unique artistic trade-offs. Because we are working with physical threads and textiles, some designs naturally translate better to one style over another. If you love the rich, tactile look of traditional embroidery, accepting a slightly softer edge on tiny details is part of that classic charm. If your application requires long periods of outdoor exposure, you may need to sacrifice some gradient or detailed elements of your design.
Unsure which patch type suits your design and application best? Please send your artwork and any project details over to trini@kwindie.com, and we will give our professional recommendation.
