What sizes are available for custom patches?
We produce patches from 1 inch to 12 inches; the most common range is 2–4 inches, and custom die-cut shapes are available.
Patch size is measured at the longest dimension of the design - the diameter for round patches, the longest edge for rectangular patches, or the longest point-to-point measurement for shaped patches. We produce patches from 1 inch (small merit badge style) up to 12 inches (large back patches for jackets).
The most popular size range is 2–4 inches, which covers the majority of sleeve patches, cap patches, chest badges, and organizational insignia. At this size range, embroidery has enough space to render text legibly and capture medium-detail imagery clearly.
Very small patches (under 2 inches) require simpler designs. Fine text and intricate imagery become difficult to read or distinguish at small scales in thread embroidery. Parker and our expert reviewers will flag designs where the detail level exceeds what's practical at your chosen size.
Large patches (5 inches and above) are popular for back patches, center-chest designs on jackets, and commemorative pieces. These sizes allow for highly detailed embroidery and more complex imagery. Per-piece prices are higher at larger sizes due to increased thread and material use.
Custom shapes - also called die-cut shapes - let you specify a patch outline that follows your design rather than using a standard round, oval, rectangle, or square border. Die-cut shapes require a small cutting die fee for first orders but allow for dramatically more distinctive patches. Parker can help you visualize shaped options.
If you're not sure what size to order, a simple rule: text should be no smaller than 1/4 inch tall to be legible in embroidery. For imagery, the more complex the design, the larger the patch needs to be to render it cleanly.
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