- Dye Sublimation Printing
- Screen Printing
- Woven Fabric Labels
- Custom Cut & Sew Manufacturing
Embroidered patches are the style most people are familiar with, having seen them on uniforms, hats, jackets, and more. Starting with a twill base, the custom design is embroidered using thread. Embroidered patches are found in three coverage amounts, 50% embroidery, 75% embroidery, and 100% embroidery. The coverage percentage refers to how much thread coverage the patch will have verses the amount of twill that will be visible. Patches that are embroidered at 50% or 75% will have a different texture, as the embroidered part will ‘rise’ off the patch.
Woven Patches are primarily used in place of embroidered patches. Since woven patches use thinner threads that are woven together instead of embroidered onto a fabric, they are ideal when a design is too detailed or complex to be achieved with the embroidery process. Woven patches are made of thread only, stitched in a continuous design. Woven patches achieve finer detail in both the design and text of the patch. Since the patch is woven, it has a smooth appearance with no raised texture. Woven patches are also a great way to achieve photographic realism. Human faces, landscapes, motorcycles, gradients, and blends can be reproduced on smaller sized woven patches in a way only possible on large embroidered patches.
Printed patches involve printing a photograph, design, or text onto a blank piece of twill fabric. Using a dye sublimation process, ink is used to fuse the design into the fabric; therefore, these patches have no color limitation—over one million colors are available. Printed patches are completely washable, dry cleanable, and fade-proof. Small print is easily readable on these patches, and they are often the best choice for those who desire photographic realism or those needing patches in an extremely short time window, as the printing process takes less time than the embroidery process.
Name patches are often found on work shirts or other applications where displaying a name is a professional identifier. They can be ordered as blank patches and embroidered locally or ordered finished and ready for final application. Since name patches are basic—with very little stitching and only one or two colors—they are less expensive than fully embroidered patches. Stylus Apparel offers them to you at a lower minimum than traditional embroidered patches: only four pieces per name. Additionally, you can order name patches in either embroidered or printed form.
Also known as Letterman Patches, chenille patches are often found on varsity jackets and sweaters and are used for awards. Usually chenille patches have two layers, a bottom felt and a top that is ‘furry’ in appearance, like that of a terry cloth robe. These patches can be made to resemble custom shapes (state and county outlines, mascots, etc), as well as letters, numbers, and even full words. Chenille patches don’t achieve the same level of detail as other types of patches, but the finish can’t be replicated.