Patches have evolved beyond military insignias to become one of the most versatile components in Canadian custom apparel. Whether we're making uniforms, lifestyle items, or promotional stuff, patches help us add texture, identity, and brand personality to every product.
For buyers or brand owners, selecting the right patch type - and right backing and finishes - can either elevate a piece from a professional look to an unfinished, inside-out feeling.
In this blog, we will discuss all we've learned at In-House about patch construction, durability, and functional designs to help you make an informed decision for your next project.
Woven vs. Embroidered vs. PVC: Understanding the Core Differences
Before we discuss backings or edges, it’s beneficial to understand how woven, embroidered, and PVC patches differ from one another. Each has its own style, durability, and best use cases.
Woven Patches
-
Texture: Smooth, fabric-like
-
Colour: Very high
-
Cost: Moderate
-
Durability: Good
-
Ideal use: Detailed logos, minimalist brands
Embroidered Patches
-
Texture: Raised, textured
-
Colour: High
-
Cost: Medium high
-
Durability: Very good
-
Ideal use: Heritage, sports, lifestyle apparel
PVC Patches
-
Texture: Rubbery, 3D
-
Colour: Bold and solid
-
Cost: Low to medium
-
Durability: Excellent
-
Ideal use: Outdoor and tactical gear, workwear
Choose the patch type that fits your brand, environment, and budget: woven for fine detail and a clean look, embroidered for texture and depth, and PVC for maximum durability in tough conditions. Once you lock the core material, you can dial in backing and edge style to match the use case and finish the piece with intention.
Backings Breakdown: Picking the Right Foundation for Function:
The type of backing you select can influence how a patch is attached and how well it holds up over time. Here are the standard types of backing and where they are generally used:
- Sew-on: The most classic application method. Stitched onto fabric permanently. This is ideal for uniforms or anything worn regularly.
- Iron-on: Uses heat to melt an adhesive. Ideal for quick custom merch embellishments when you don't have a sewing machine.
- Velcro: Two-piece backing (hook and loop). Ideal for gear and uniforms that require the patch to be removed or exchanged frequently.
- Adhesive: Best for temporary uses. For example, sample runs, short campaigns, or promotional runs.
When it comes to Canadian custom apparel, depending on the fabric, you should select a backing for patches like this:
-
Cotton or fleece: Iron-on or sew-on both work well.
-
Nylon or rugged outer shells: Velcro or sew-on work better for reliability.
Choose the backing that matches wear, wash, and swap needs. Then test on a fabric swatch to confirm adhesion and durability before you run production.
Edge Styles Explained: Clean Finishes That Define Quality
The edges of a patch are just as important as the front - they are an indicator of how quality it was constructed.
- Merrowed Edge: A traditional, overlocked edge that creates a rounded edge. This is a perfect fit for a classic shape, and always has a vintage or traditional/contemporary look.
- Laser Cut Edge: Precision is what laser cutting is all about. Laser cutting creates smooth, sharp edges and is beneficial for complex or modern shapes.
- Heat Sealed Edge: Most commonly seen with PVC. It creates a clean, flat look and suits a clean, minimal style.
- Choosing an edge style will help reinforce brand identity: A rounded merrowed edge gives a heritage/retro feel; a precision laser cut edge feels modern; and heat-sealed edges (especially with PVC) have rugged functionality and feel.
Choose the edge that matches your brand, garment, and use case so the patch looks intentional on day one and wears well for years.
Wash Tests & Durability: Real-World Proof of Quality
Durability is not just a buzzword; it's important when you are investing in patches for uniforms, resale merchandise, or everyday wear. Here’s how various types of patches perform in different situations:
-
Machine Wash Cycles: Both embroidered and woven patches generally hold up through many wash cycles as long as they are sewn on or reinforced properly. PVC patches, since they are synthetic materials, are extremely resilient to fraying and distortion.
-
Heat & Wetness: On the heat front, a PVC patch is the way to go in hot environments (or wet environments as well); iron-on backing could break down if repeatedly heated and should be used properly.
-
Outdoor Conditions: PVC is weather-resistant and makes a good option for gear that is wet, snowy, or experiencing abrasion. Woven and embroidered patches will wear as well, but will need some more care with UV or wetness over time, especially after many washes.
If you use more sustainable materials (organic cotton for the base of the patch, recycled threads) and reinforce the stitching, you also extend durability. This is also great if you're a brand concerned about ethical production.
Design Meets Function: Tips for Choosing the Right Patch Type
Here are some practical tips learned from experience for ensuring your patches serve a dual role of form and function:
Match form and function:
-
Woven patches are best for defined, refined aesthetics where clean detail is important.
-
Embroidered patches work well when you want a textured, heritage-inspired look that feels traditional and expressive.
-
PVC patches are ideal for stylish, bold statements, especially when durability and a modern edge are priorities.
Consider where the patch will be placed:
-
Sleeves or the chest of a jacket are well-suited to embroidered or woven patches, since both styles sit cleanly on structured fabric.
-
Adjustable caps or tote bags can use iron-on or sew-on patches, depending on the fabric and the level of durability needed.
Outdoor gear, tactical bags, and rugged equipment are best paired with PVC patches using Velcro or sew-on application for secure, long-lasting performance.
Utilize them in your promotional strategy:
-
Patches also make great limited-edition giveaways or value-added bonuses in your promotional strategy.
-
If it is promotional material, iron-on or adhesive backings can minimise labour.
-
If they are for uniforms or resale merch, invest in sew-on or Velcro-backed patches for durability.
Lock design, placement, and backing to the real-world use case, then test a small run to confirm look, feel, and longevity before scaling.
Why Quality Production Matters: From Concept to Stitch
Creating your patch is only half the fun. The other half is the precision in manufacture, the consistency in stitching, and doing wash-testing. Without precision, consistency, and wash testing, even the best design might look inexpensive or fall apart quickly.
That is where In-House comes in. We don’t simply provide a design; we provide guidance through:
-
The digitization and production-ready files
-
Various materials (thread types, base fabric, backing)
-
A sustainable production and reinforcement option
-
Stringent quality checks (including wash testing)
You can learn more about how we go about doing this in our Product Research & Development process.
Bringing It All Together: Branding with Patches
Patches serve more than to be stylish; they also tell stories. They reinforce brand identity, history, or values when chosen wisely.
At In-House, we help you:
-
Create a patch to serve the purpose of your brand and represent some part of your story, not "just" because it looks cool.
-
Determine materials and finishes that best fit the brand story (eco-friendly, rugged, premium, etc.).
-
Increase production capacity sustainably and without sacrificing quality.
From concept to packaging, we help connect your branded apparel strategy. To see more, visit our manufacturing page.
Why In-House Is the Partner of Choice for Custom Apparel & Branding
With over 30 years of combined experience in product design, manufacturing, and brand development, as a Vancouver, Canadian creative agency, we appreciate the art and business of apparel.
We provide a complete package of services, guiding you through:
Concept → sample → quantities → packaging — all ‘in-house’!
We have produced high-quality custom merchandise for Canadian entrepreneurs, sports teams, and indie apparel brands.
Make Every Stitch Tell Your Story
Selecting a favourable type of patch, backing, and finish will make your branded merchandise not just look professional, but will also last. From standard patches to embroidered patches, or PVC patches, patches can enhance the story of your brand by hinting at the quality of your merchandise that your customer expects from your brand.
If you want to speak about patches, either woven, embroidered, PVC, or a wider solution across branded apparel environments, we can help you.
Let's start your next custom merchandise project with In-House, which specialises in design and production. Explore our Custom Screen Printing Canada services.
