Custom patches are a versatile way to promote a brand, personalize clothing, or add character to uniforms, jackets, hats, bags, and more. But to get the best results, it’s important to match the right patch style with the right fabric. Each fabric behaves differently, since some stretch, some are heat-sensitive, and some require stronger backing options for long-term durability. Understanding how to customize patches for each material ensures your designs hold up, look great, and stay securely attached.
Types of Patches and How to Make Them Pop
Whether you’re creating patches for apparel, promotional items, or accessories, here’s how to choose and customize the best patch type based on the fabric you’re working with.
Embroidered Patches
Embroidered patches offer a classic, textured look created with stitched thread on a twill backing. They’re ideal for thicker, more durable fabrics.
Customization Tips:
- Choose a high thread count if your fabric is rugged, this improves clarity against textured materials.
- Use iron-on backing only on heat-tolerant fabrics, as delicate fabrics may scorch.
- For stretch fabrics, opt for sew-on to avoid puckering.
- Match border styles to fabric thickness, merrowed borders work well on stiff fabrics, and laser-cut borders suit curved or intricate shapes.
Best Fabric for Application:
✓ Denim
✓ Canvas
✓ Heavy cotton
✓ Jackets and uniforms
Dye Sublimation (Printed) Patches
Dye sublimation patches use a printing process that embeds ink directly into the patch material. They are perfect for highly detailed or photo-realistic designs.
Customization Tips:
- Use dye sublimation when your fabric has fine textures, as printed patches won’t catch on the material.
- Opt for heat-transfer backing on polyester, which handles heat well.
- Avoid using on nylon or heat-sensitive fabrics, unless applying a sew-on border.
- Choose a thin border or no border to maintain a sleek look on performance apparel.
Best Fabric for Application:
✓ Polyester fabrics
✓ Lightweight outerwear
✓ Stretch fabrics
✓ Athletic apparel
PVC (Rubber) Patches
PVC patches are flexible, waterproof, and highly durable. Their 3D rubberized appearance makes them ideal for outdoor gear and workwear.
Customization Tips:
- Select PVC for fabrics that face moisture or rough conditions, as they are weather-resistant.
- Use hook and loop backing for tactical gear or removable patches.
- Choose adhesive or sew-on for jackets and bags, depending on usage.
- Avoid heat application, as PVC should never be ironed onto any fabric.
Best Fabric for Application:
✓ Nylon
✓ Polyester
✓ Backpacks and tactical gear
✓ Rainwear and outerwear
Chenille Patches
Chenille patches create a fuzzy, textured look thanks to yarn-like pile, most commonly seen on varsity letters and jackets.
Customization Tips:
- Use chenille on fabrics that provide structure, since the patch is thick and plush.
- Pair with felt backings for a layered varsity look.
- Stick to simple shapes and large lettering, as chenille is not suited for small details.
- Choose sew-on application to support the patch’s weight.
Best Fabric for Application:
✓ Wool
✓ Fleece
✓ Heavy cotton
✓ Letterman jackets
Final Tips for Matching Patch Type to Fabric
When customizing patches, your goal is to balance durability, aesthetics, and practicality. Thick fabrics can handle heavier patches like chenille, PVC, and embroidered styles, while lightweight or stretch fabrics pair best with woven or dye sublimation patches. These factors help ensure your patches stay vibrant, durable, and secure over time. Always consider:
- The fabric’s thickness
- The item’s intended use
- Whether the fabric can handle heat
- Washing and wear requirements
Ready to Create Custom Patches?
If you’re looking for high-quality custom patches that suit your fabric type, contact American Patch today. Our team can help you choose the perfect patch style, backing, and design features, and provide a fast, competitive quote for your next project.