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How to Order Custom Patches Online: A Step-by-Step Guide
Ordering custom patches online should be simple. However, between choosing a patch type, preparing your artwork, understanding backing options, and figuring out what to ask your supplier, it can feel surprisingly overwhelming for first-time buyers.
In this step-by-step guide, we walk you through the entire process — from your initial idea all the way to holding your finished patches in your hands. Whether you are ordering for a business, a team, a personal project, or an event, you will know exactly what to expect and how to get the best possible result.
Step 1: Define What You Need Before You Start
Before you contact any patch maker, it helps to have a clear picture of what you need. First, think through these key questions:
- What is the patch for? A uniform, merchandise, a gift, an event, or personal use?
- How many do you need? One prototype, a small batch, or a bulk order?
- What size do you need? Small (1–2 inches), medium (3–4 inches), or large (5 inches and above)?
- Do you have a deadline? Standard lead times are typically 10–14 days after design approval.
Step 2: Choose Your Patch Type
Embroidered Patches
Embroidered patches are the most popular choice. Stitched thread on a fabric backing creates a raised, textured, three-dimensional surface. Best for: bold logos, team emblems, uniforms, jackets, and merchandise.
Woven Patches
Woven patches are made on a loom with thin thread, producing a flat, smooth surface with exceptional fine detail. Best for: complex logos, small text, clothing labels, and professional badges.
PVC Patches
PVC patches are molded from flexible rubber-like material, creating a waterproof, three-dimensional patch with a modern look. Best for: outdoor gear, tactical equipment, and contemporary branding.
Chenille Patches
Chenille patches use looped yarn to create a soft, plush, velvet-like surface. Best for: letterman jackets, varsity apparel, fashion brands, and premium loyalty rewards.
Printed Patches
Printed patches use dye-sublimation to reproduce full-color photographic images and unlimited colors. Best for: photography, complex multi-color artwork, and event merchandise.
Step 3: Prepare Your Artwork
- Vector files (AI, EPS, SVG, PDF): The best option. Vector artwork scales to any size without losing quality.
- High-resolution raster (PNG, JPEG, TIFF): Acceptable if the resolution is 300 DPI or higher at the intended patch size.
- Rough sketches or ideas: Even a clear hand-drawn sketch can be enough to get started — the design team will develop your concept.
Step 4: Choose Your Size
- 1–1.5 inches: Very small — ideal for hat pins, lapel badges, and small labels.
- 2–3 inches: The most common range. Works well on bags, hats, shirt sleeves, and chest patches on jackets.
- 3–4 inches: Medium-large. Gives strong visual presence on jackets, backpacks, and shoulder patches.
- 4–6 inches: Large patches for jacket backs, vests, and large garment areas.
Step 5: Choose Your Backing Type
Iron-On Backing
A heat-activated adhesive bonds to fabric when pressed with a hot iron for 30–60 seconds. This is the most convenient option for customers applying patches at home. However, for items washed frequently, combine iron-on with a few stitches around the edges for a more permanent hold.
Sew-On Backing
The most permanent and durable attachment method. As a result, it is the best choice for uniforms, workwear, and items that will be washed frequently or used heavily.
Velcro Backing
A hook-and-loop system. This is ideal for items where patches need to be swapped, removed, or repositioned — for example, tactical vests and rotating branded items.
Step 6: Submit Your Order and Get Your Free Mock-Up
- First, fill out the contact form at xpresspatches.us/contact-us with your design file, patch type, size, quantity, and backing preference.
- Next, receive your free digital mock-up within 24 hours. You will see exactly how your patch will look before any production begins.
- Then, review and request revisions if needed. Most revisions are turned around within a few hours.
- After that, approve your mock-up and confirm your order.
- Finally, receive your patches in 14 days or less.
Frequently Asked Questions
How long does it take to get custom patches made?
First, you will get a free digital mock-up within 24 hours. After that, production and shipping takes 14 days or less. Rush orders are also available if you need patches sooner.
What is the minimum order quantity for custom patches?
There is no minimum. You can order a single patch. Most customers start with a test run of 5–25 patches before scaling up to larger quantities.
Can I order patches if I do not have a finished design?
Yes. Simply submit a rough sketch, description, or reference image. The design team will develop it into a patch-ready design shown in your free mock-up before you commit.
What if I am not happy with my patches when they arrive?
Every order is covered by a 100% money-back satisfaction guarantee. Therefore, if there is a quality issue, simply contact Xpress Patches immediately for a replacement or full refund.
Ready to Order Your Custom Patches?
In summary, ordering custom patches online is simple when you know what to expect. No minimums, no hidden fees, 100% satisfaction guaranteed, and USA-based craftsmanship with 14-day delivery.
