One clear reference for choosing a craft, planning a design and understanding what changes the limits of a custom patch. It brings together the craft combinations we produce, the minimum finished sizes we work to, the thread colors included in a quote, the size tolerance to expect, and the substitute craft we recommend when artwork is too detailed for the one you picked.
Some artwork reads best when two crafts share one patch: a raised, stitched element paired with a flat or full-color area. These are the three established combinations we build, and the mix is confirmed with you at the proofing stage.
A flat, finely woven base or detail area combined with raised embroidery. This pairing is the usual answer when one patch has to carry both a textured logo mark and a line of small, crisp text.
Typically used for: uniform badges, corporate logos with fine lettering, and brand marks that need a textured centre with a clean, flat edge.
Dimensional chenille yarn combined with embroidered detail and outline. The chenille gives the patch its raised, retro feel while the embroidery holds the letter edges and fine outlines that chenille alone cannot resolve.
Typically used for: letterman and varsity patches, team names, and large bold letterforms with a stitched outline.
A stitched border or stitched outline combined with a printed interior. This lets a patch keep the durability and finish of embroidery while reproducing gradients, photos or a very high color count in the centre.
Typically used for: full-color artwork with a stitched edge, photo patches, and multi-color graphic logos.
The final mix is confirmed at proofing. How much fine detail, texture and color coverage the artwork needs decides whether one craft is enough or whether two crafts should be combined — and we show you the result on a proof before production begins.
How small a patch can go depends on the craft, because each one reproduces small text and fine lines differently. The figures below are the practical starting points we work to.
| Craft | Recommended minimum finished size | What to keep in mind |
|---|---|---|
| Embroidered patches | 2 in (≈ 51 mm) recommended | Below this, thread coverage and small text become hard to hold. Bold, simple artwork holds up best at the small end. |
| Woven patches | 1 in (≈ 25 mm) | Tight, flat weaving keeps small text and fine lines legible, so woven tolerates a smaller footprint than embroidery. |
| Printed patches | 1 in (≈ 25 mm) | Full-color print holds gradients and fine detail; the smallest sizes suit simple, high-contrast artwork. |
Each craft includes a set number of colors in the price. Beyond that, additional colors on embroidery and woven are charged individually, while printed patches carry no color limit at all.
| Craft | Colors included free | Maximum colors | Extra color charge |
|---|---|---|---|
| Embroidery | Up to 9 colors | Reviewed per design | Each color beyond the 9 included adds a charge |
| Woven | Up to 8 colors | 12 colors | Each color beyond the 8 included adds a charge |
| Printed | No color limit | No color limit | None — color count is not charged |
There is no single universal number for these two limits — they move with the font and the design. That is why we review them against your actual file and target size rather than quoting one figure for every job.
It depends on the font. A condensed, serif or script face needs more height to stay readable than a bold sans-serif, and the same letter height can look completely different depending on weight and letter spacing.
What we do: the smallest readable text is confirmed with you at the proof stage, before production.
It depends on the design. Thin strokes, hairlines and very fine outlines have a practical floor, and that floor changes with the craft — woven holds the finest lines, while embroidery holds the thickest.
What we do: any stroke that will not reproduce cleanly is flagged, and we suggest a small adjustment to keep the detail.
Because text height and line width are design-specific, we do not publish one universal figure. Send your file together with the finished size and we will tell you which elements need to change — free of charge, before you approve production.
On smaller finished patches, dimensional variation is typically about 1–2 mm. This is normal for stitched and woven goods and applies to length, width and the cut outline. Larger sizes, tight outlines and some materials can open the tolerance further, so if a patch has to sit inside an exact opening, recess or frame, tell us at the quoting stage and we will confirm the achievable tolerance in writing.
Color also needs a small allowance. Thread and yarn colors can differ slightly from a screen preview, and slight variation can occur between production batches, so the approved physical or digital proof is the color reference for the order.
If a design cannot be reproduced in the selected craft, we do not silently downgrade it — we recommend the craft that is closest to your original idea and explain the difference.
Fine lines, small text or soft gradients may not hold in embroidery, where thread thickness sets a firm floor.
›Flat weaving captures finer lines, smaller text and smoother detail, so woven is the usual substitute when embroidery cannot hold the artwork.
›Photos, blends, gradients or an unusually high color count are beyond woven reproduction and are best produced as printed patches.
Alongside craft, size and color count, the following choices are confirmed with you before production.
The five questions buyers ask most often after reading this guide.
For embroidered patches we recommend a minimum finished size of 2 inches (about 51 mm). Woven and printed patches can be produced as small as 1 inch (about 25 mm). Very dense or very fine artwork can push the practical minimum up, so the smallest usable size is confirmed against your design before production.
Embroidered patches include up to 9 colors at no extra cost, and each additional color adds a charge. Woven patches include up to 8 colors, support a maximum of 12 colors, and each color beyond the 8 included adds a charge. Printed patches have no color limit and are not charged by color count.
On smaller patches, dimensional variation is typically about 1–2 mm, covering length, width and the cut outline. Larger sizes, tight outlines and some materials can open the tolerance further, so if your patch must fit an exact opening or recess, tell us when you request a quote and we will confirm the achievable tolerance in writing.
Yes. We produce embroidery combined with woven, embroidery combined with chenille, and embroidery combined with printing. The right combination is chosen from the amount of fine detail, the texture you want and the color coverage in the artwork, and it is confirmed on a proof before production.
Artwork that is too complex for embroidery is usually redirected to woven patches, and artwork that is still too detailed for woven is typically produced as printed patches. Where only part of the design is over-detailed, we can also combine crafts — for example a stitched border with a woven or printed centre. The recommendation is confirmed after reviewing your file and the intended size.
Not sure which craft fits your artwork? Send the file and the finished size you have in mind. We will confirm the craft, the size and the color count that will reproduce it cleanly, and show you a proof before anything goes into production.
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