Types of Custom Patches: Embroidered, Woven, PVC, Chenille & More
Everyone says "patch" and pictures an embroidered one. But there are six common types, and the right pick depends entirely on your design and where it's going. Bold logo on a work jacket? Embroidered. Intricate crest with tiny text? Woven. Rugged tag for a backpack? PVC. Here's the full rundown.
Embroidered
The classic. Thread stitched over a twill base, with that familiar raised texture. It looks premium on caps, jackets, and workwear, and it's what most people want. The limit is detail — thread can only get so fine, so small text under about 5 mm and photo-style gradients don't translate. That's a digitizing reality, not a shop cutting corners.
Woven
Made on a loom with much thinner threads than embroidery uses. The payoff: it holds way more detail, sits flat and thin, and handles small text and complex crests that embroidery would blur. The tradeoff: you lose the raised, textured feel. For a busy design, woven is often the smarter choice even though people default to embroidered.
PVC (rubber)
Molded soft plastic, not fabric. Waterproof, nearly indestructible, and it can do crisp 3D relief. This is the tactical and outdoor favorite — morale patches, gear, anything that'll get rained on or thrown around. Downside: it doesn't have that fabric-and-thread look, so it's the wrong vibe for a heritage brand or a varsity jacket.
Chenille
The fuzzy, plush "varsity letter" patch. Big, bold, tactile — perfect for letterman jackets, team spirit, and retro apparel. Not for fine detail; chenille is all about large simple shapes and letters.
Printed / sublimated
Your artwork printed directly onto fabric. Handles full-color photos, gradients, and unlimited detail with no thread limits at all. Cheapest for complex art, thinnest profile — but it lacks any texture and won't feel as premium as embroidery or weave.
Leather (and faux leather)
Debossed or printed leather patches — the look you see on premium caps and denim. Great for a rugged, upscale brand feel. More of a style statement than a detail workhorse.
Quick way to choose
- Bold logo, classic feel → embroidered
- Fine detail or small text → woven
- Outdoor / tactical / waterproof → PVC
- Varsity / plush / big letters → chenille
- Full-color or photographic → printed
- Premium, rugged branding → leather
Still deciding? Send us the artwork and how you'll use it and we'll tell you honestly which type gives the best result — including your backing options. Get a quote or see our services.