Choose embroidered for the classic raised, stitched look and bold designs; woven for fine detail and small text; PVC for a waterproof, rugged rubber patch with raised 3D detail; UV + PVC when you need waterproof full color; and sublimated for photo-quality full-color prints on fabric. Price is close across all five, so pick on looks and use first.
This guide compares how each patch type is made, what it looks like, where it works best and what it costs at Legion Patches, so you can choose in a few minutes.
The five types side by side
| Embroidered | Woven | PVC | UV + PVC | Sublimated | |
|---|---|---|---|---|---|
| Made from | Thread stitched on twill | Fine thread woven on a loom | Molded soft PVC rubber | UV print on soft PVC | Dye printed into polyester fabric |
| Look and feel | Raised, textured | Flat, smooth, thin | Raised 3D, rubbery | Smooth, full color | Flat, smooth, full color |
| Fine detail and small text | Fair | Excellent | Good | Excellent | Excellent |
| Gradients and photos | No | No | No | Yes | Yes |
| Waterproof | No | No | Yes | Yes | No |
| Best for | Clubs, uniforms, jackets, caps | Detailed logos, name tabs, brand labels | Morale, tactical, outdoor gear | Full-color logos, merch, bags | Photos, full-color logos, events, teams |
| 100 at 3 in, each | $3.67 | $3.20 | $4.51 | $4.14 | $3.36 |
Prices are per patch with sew-on backing, from our live price list. The full tables are on each type’s page.
Embroidered patches: the classic look
Embroidered patches are stitched in thread on a twill base. The stitches sit on top of the fabric, so the design is raised and has a texture you can feel. It is the look most people picture when they think of a patch: club vests, fire department shoulders, team jackets, scout badges.
- Strengths: bold, traditional, hard wearing, rich thread colors.
- Limits: thread has a minimum thickness, so very small text and hairline detail can blur. Text needs to be about 1/4 inch (6 mm) tall or more.
- Choose it when: your design has bold shapes and clear lettering, and you want the traditional stitched look.
Woven patches: maximum detail
Woven patches are made on a loom with much finer thread, woven flat and tight. Because the thread is thinner, woven patches hold small text, thin lines and detailed artwork that embroidery cannot. They are thinner, lighter and smoother than embroidered patches.
- Strengths: sharp detail, small text down to about 1/8 inch (3 mm), flat profile, often the lowest price.
- Limits: less raised texture, so they look less “stitched” than embroidery.
- Choose it when: your logo is detailed, your text is small, or you want a clean, flat, premium finish for clothing brands and name tabs.
PVC patches: tough and waterproof
PVC patches are molded from soft PVC rubber. Each color is its own layer, and parts of the design can be raised for a 3D effect with crisp edges. PVC is flexible, waterproof and very hard wearing.
- Strengths: waterproof, wipe-clean, raised 3D detail, survives rough use.
- Limits: works best with solid colors and bold shapes; not suited to gradients or photos.
- Choose it when: the patch goes on outdoor, tactical or work gear, or you want the modern rubber look. Pair it with Velcro for morale patches.
UV + PVC patches: full color
UV + PVC patches combine a full-color UV print with a soft PVC base. The print can carry gradients, shading and photo-style artwork that thread and molded PVC cannot, while the PVC body keeps it waterproof.
- Strengths: any color, gradients and photo detail, fine detail, waterproof.
- Limits: a smooth printed surface rather than raised, sculpted layers.
- Choose it when: your artwork is full color or illustrated and must look the way it does on screen.
Sublimated patches: photo-quality print
Sublimated patches are printed, not stitched. Sublimation ink is heat-bonded into smooth polyester fabric, so the color becomes part of the patch. There is no limit on colors, so photos, gradients and fine detail come through as they look on screen.
- Strengths: unlimited colors, photo detail, smooth flat finish, light and thin.
- Limits: no raised texture, and it is fabric, so it is not waterproof.
- Choose it when: your design is a photo, a detailed illustration or a logo with gradients, and it goes on clothing, caps or bags.
Quick decision guide
| If you need… | Choose |
|---|---|
| The traditional stitched look | Embroidered |
| Small text or a very detailed logo | Woven |
| Something waterproof and rugged | PVC |
| Gradients, shading or a photo on fabric | Sublimated |
| Full color that is also waterproof | UV + PVC |
| The lowest price per patch | Woven or embroidered, at larger quantities |
| Patches for a club vest | Embroidered |
| Patches for a plate carrier or range bag | PVC with Velcro |
| Labels for a clothing brand | Woven |
Still unsure? Many orders mix types: embroidered back patches with woven name tabs, or a PVC morale patch alongside an embroidered uniform patch. Each design is its own order line with its own 25-piece minimum.
How price compares across types
All four types sit in a similar price range, and quantity changes the price far more than type does. For 3 inch patches with sew-on backing, from the Legion Patches price list:
| Quantity | Embroidered | Woven | PVC | UV + PVC | Sublimated |
|---|---|---|---|---|---|
| 50 | $3.95 | $3.38 | $5.45 | $5.26 | $3.55 |
| 100 | $3.67 | $3.20 | $4.51 | $4.14 | $3.36 |
| 250 | $2.96 | $2.83 | $3.49 | $3.32 | $2.97 |
| 500 | $2.73 | $2.44 | $3.10 | $3.01 | $2.56 |
| 1,000 | $2.16 | $1.97 | $2.44 | $2.35 | $2.07 |
See how much custom patches cost for sizes, backings and totals.
How each type is made
Knowing how a patch is made explains why each type looks and behaves the way it does.
- Embroidered: your design is turned into a stitch file, then an embroidery machine sews thread onto a twill base, color by color. The edge is finished with a stitched (merrowed) border or cut to shape. Thread thickness sets the smallest detail it can show.
- Woven: the design is woven into the fabric on a loom, using fine thread for both the background and the artwork. Because the whole patch is woven at once, it is flat and holds tiny detail.
- PVC: a mold is made from your design. Liquid PVC is filled into the mold one color at a time, then cured into a soft, flexible rubber patch with raised and recessed areas.
- UV + PVC: a soft PVC base is made in your shape, then your artwork is printed onto it in full color with UV-cured ink, which bonds to the surface and resists fading and water.
Whatever the type, every Legion Patches order follows the same steps: a free digital mockup within 6 hours, a physical sample in 2 to 3 days, then about 2 weeks of production after you approve the sample. The sample is your chance to see and feel the type you chose before the full run is made.
Common mistakes
- Choosing embroidery for tiny text. Small lettering blurs in thread. Go woven or make the text bigger.
- Choosing PVC for a photo or gradient. Molded PVC uses solid color layers. Pick UV + PVC.
- Choosing embroidery for wet gear. Thread soaks up water and dirt. PVC wipes clean.
- Deciding on price alone. The difference between types is small. Pick the one that suits the design and the use.
- Skipping the mockup review. Your free mockup shows how your design will look in that type. Use it to compare.
Frequently asked questions
What is the difference between embroidered and woven patches?
Embroidered patches use thicker thread stitched on top of a base, giving raised texture but less fine detail. Woven patches use thinner thread woven flat, so they hold small text and detail and feel smooth.
Are PVC patches better than embroidered?
Neither is better overall. PVC is waterproof, flexible and shows raised 3D detail, so it suits outdoor and tactical gear. Embroidery gives the classic stitched look and suits clubs, uniforms and jackets.
Which patch type is the cheapest?
Woven is often slightly cheaper than embroidered at the same size and quantity. Quantity affects price far more than type: larger orders cost much less per patch.
What is a UV PVC patch?
A soft PVC patch with artwork printed in full color using UV printing. It handles gradients and photo detail and is waterproof.
Which patch type lasts longest?
All four last for years when attached properly. PVC and UV + PVC handle water and rough use best; embroidered and woven patches hold up well on clothing and are best sewn on.
See your design in any patch type
Pick a type on the quote page and see your price instantly. You get a free digital mockup within 6 hours and a physical sample before production. Want a recommendation for your design? Message us on WhatsApp at +1-437-703-7747.