What patch digitizing covers
A patch file is not the same as a logo file for a shirt. On a shirt, the garment is the background and the logo only needs to cover its own shapes. On a patch, the file has to build the whole object: background, design, edge and sometimes a line to cut along. Density, underlay and sequence all change because the patch has to stay flat and hold its shape once it is cut free from the hoop.
We digitize by hand for the way you make patches, so tell us your base material, border style and backing in the order form.
We are a digitizing studio. We do not manufacture, sew or ship patches. You receive the embroidery file, a stitch simulation proof and a PDF worksheet, ready for your machine or your patch producer.
Full embroidered background or twill base
The first decision on any embroidered patch digitizing job is what fills the background.
| Base style | How it is built | When to use it |
|---|---|---|
| Full fill (100% embroidered) | A tatami fill covers the entire patch area, then the design sews on top. | Classic patch look, any background color, maximum durability. |
| Twill base | The twill fabric color is the background; only the design and border are stitched. | Lower stitch count, faster runs, softer patch. Popular for club and uniform patches. |
| Partial fill | Fill in some areas, twill showing in others. | Designs with large open areas where a matching twill color saves stitches. |
For full fill patches, we plan the background so design elements on top do not pile up excessive density. Where a top element sits over the background, we either cut the background out underneath or lighten the layer, so the patch does not become stiff or pucker. Our guide to embroidery underlay and density explains the trade-off in more detail.
Satin border vs merrow border
The border is where patch files most often go wrong, and it depends on how you finish the patch.
Satin border (sewn in the file)
A satin border is part of the embroidery file. It sews last, around the outside of the patch, and covers the edge of the base. It works for almost any shape, including sharp corners, custom outlines and die-cut shapes. Satin borders on patches are usually wider than a regular outline to cover the cut edge fully and hold up to wear.
A common workflow is to sew the design, cut the patch out close to the border (hot knife, laser or scissors), and let the border seal the edge. Some shops cut before the final border pass, and we can add a stop for that.
Merrow border (sewn on a separate machine)
A merrow border is an overlock edge wrapped around the patch on a dedicated merrow machine after the patch is cut out. It is not in the embroidery file. What the file needs is a clean edge for the merrow to wrap over:
- The background ends in an even, finished edge with no stray stitches or ragged fill ends.
- A small margin is left so the merrow stitch covers the edge without biting into the design.
- The shape stays simple. Merrow edging suits circles, ovals, squares, rectangles and shields with gentle corners. Sharp inside corners and complex outlines need a satin border instead.
If you order a merrow border patch file, tell us the merrow width you use and we will set the margin to suit.
Cut lines and finishing
Depending on your cutting method, we add:
- A cut line run: a single run stitch just outside the final shape, as a guide for a hot knife or scissors.
- A stop before the border: for shops that cut the patch out before the satin border sews.
- Registration for laser cutting: tell us your process and we match the outline to your cut path as closely as the stitch file allows.
Heat-seal backing is applied after embroidery with a heat press, so it does not change the stitch file itself. It does affect how the patch will be used. Heat seal bonds best to a flat patch back, so we keep dense stacks and bulky underlay to a minimum on patches meant for heat seal. Iron-on patches on stretchy or textured garments still benefit from a few stitches around the edge after pressing.
Patch sizes and detail
Most custom patches are 2 to 4 in across, with 3 in a common size for club, uniform and brand patches. At that size, detail has limits:
- Satin lettering should stay at roughly 0.2 to 0.25 in tall or larger to read clearly.
- Fine lines narrower than about 1 mm are dropped, thickened or turned into run stitches.
- Very small patches (under 2 in) usually need simplified artwork and fewer colors.
If your artwork has more detail than a patch can hold, we simplify it and show you on the proof. Revisions are unlimited until you approve. For help getting artwork ready, see our guide to artwork for embroidery digitizing.
Patch digitizing price
Patch files are priced by finished size, like all our embroidery work, plus $5 when the file includes the patch border setup:
- Up to 4.5 in: $14
- Up to 8 in: $24
- Up to 12 in: $39
- Border: plus $5
Most patches fall in the small size. Every order includes DST, PES, EXP, JEF, VP3, XXX, HUS, VIP and other formats on request, plus the PDF worksheet with stitch count and color sequence. Rush and express turnaround are available on every patch order.
Ready to turn your design into a custom patch embroidery file? Upload your patch artwork and choose patch as the placement.
Other patch types
Chenille patches, such as letterman patches, use a different machine and file type. See chenille digitizing. Woven, printed and PVC patches are not embroidery, so they do not use a stitch file. If you need clean vector art for those, our vector art conversion service can prepare it.
