Custom Woven and Embroidered Patches are staple products at Studio Dais and the demand for them is slowly nearing that of our hard enamel and soft enamel pins. Will custom woven and embroidered patches be the custom merchandise items of 2021? This detailed and in-depth article aims to convince you that they will be! We will be answering questions you have emailed in as well as expounding on other woven and embroidered patch queries we see all over the internet. We aim to clear up confusion and muddled answers we see from a variety of sub-par producers. Let’s go!
Custom Woven Patches Vs Custom Embroidered Patches. What Is the Difference?
Before we dive head-first into this article, let’s first clarify we can make many different styles of patches other than woven and embroidered styles:
To name but a few. We will explore the other various types of patches in future blog posts but for now let’s make one important point!
Custom Woven Patches Vs Custom Embroidered Patches. What Is The Difference?
Custom woven and embroidered patches are the two core patch products Studio Dais manufacture for our customers (with Chenille patches slowly on the ride). They are up there with soft enamel lapel pins and hard enamel pin badges in terms of volume and output. Although the terms ‘weaving’ and ‘embroidery’ are used interchangeably there is a stark difference in the manufacturing process, and it is this important difference you need to be aware of when you are deciding which patch style is right for your brand. Let’s find out!
How Are Custom Woven Patches Made?
When we ‘weave’ your custom made woven patches, we weave an entirely new piece of fabric (as opposed to embroidering an existing piece of fabric as you will read below). This process involves using two sets of threads and yarns and by the method of interlacing, we are manufacturing textiles from scratch! In order to keep the warp threads and filling threads in place, we also use a loom to keep things tight and in place. And voila, like magic this is how we manufacture your custom made woven patches! Patches are created out of thin air! Sort of.
Woven Patch Finishing Touches. Overlocked / Merrow and Heatcut / Hotcut Edges
Woven patches come in a variety of finishes. The edges can be overlocked which is a neat sewn hem edge all around the patch outline (including on die-cut to shape patches also). Overlocked edge is our most popular finish as it really makes the patches pop with a slightly raised surface edge, roughly 2.5mm in thickness! The other option is heat cut finish. This option is perfect for more traditional clubs and groups who need a simpler looking product. Heat cut patches are usually best applied with either sticky application or iron on for a smooth and flat appearance.
Woven Patch Fixing Application. Sew On, Iron On, Sticky and Velcro Attachment
We offer three types of patch fixing application.
Sew on: This is our most popular method. This involves the patches being sewn onto the garment directly. You can do this sewing by hand or with either a domestic or professional sewing machine. Sewing is a relatively simple process, and if you are unable to do this yourself you can find a number of companies on the high street or online who can do this for you.
Iron on: Another popular option is iron on. During the manufacturing stages we can apply a strong industrial strength iron on application pad. You would then use a hot iron to iron the woven patches to your garments. You could also sew on iron on patches for extra strength!
Sticky application: This is a good method for when you need quick applications, and for patches that are not intended to be adhered more than a week. The sticky option is high strength, but will come off in the wash eventually. Sticky application is good for school sports day events, business fund raiser events and other day events. The bonus is the wearers of the patches are able to take them off easily and take home as a brand keep-sake.
Velcro Patch: The final option is Velcro application. This is a great option if you want your patches to be interchangeable or if you are creating patches for heavy duty work wear and / or military applications. The Velcro is industrial strength and will take some pulling to get them off. Our fashion clients also choose this option if they want to release a series of limited edition patches over the period of say a year where their customers can buy them as and when they drop.
What This All Means for Your Woven Patches
Woven Patches Have Greater Details
The above process gives us a much more detailed patch as the design is created from scratch using extremely thin threads. Whereas embroidered patches are limited to the base fabric backing, woven patches are not, and this is why woven patches are ideal for designs with more detail. Such as text, facial details and some essential small colour details that without them, would otherwise make the design void.
Woven Patches Are Affordable
Generally speaking, custom woven patches are 20% cheaper than embroidered patches due to a simpler manufacturing process. No matter how technical or complicated your design is, we are able to keep your design on point and under budget.
Woven Patches Are Versatile
There is a reason we manufacture and sell more custom woven patches than we do custom embroidered patches. Woven patches are extremely versatile! They can be applied to more types of clothing garments and accessories, such as shirts, jumpers, coats, beanies, hats and all types of bags + backpacks. Woven patches are thinner and more flexible than our custom made embroidered patches, as well as being much less abrasive on your skin as well as having a much more resistant surface, so no snagging or pulling here!
How Are Embroidered Patches Made?
Our custom made embroidered patches are as you guessed it, embroidered. But what exactly is embroidery? Embroidery is classed as ‘the art or pastime of embroidering cloth’. ‘Cloth’ being a key word here. You see, when we embroider your embroidered patches, we use a fabric backing (cloth) aka twill, and embroider your design onto the cloth / twill. This is a stark contrast to our woven patches whereby we essentially weave that ‘cloth’ or ’twill’ out of thin air using the weaving technique.
Embroidered Patches Are Just Decorated Cloth
In essence, embroidered patches are really just ‘decorating’ cloth with your designs and with that comes some limitations. We have to use thicker threads which means a less detailed design, but this does have its advantages, as you will read below. We recommend our custom made embroidered patches for military or military re-creation, security units, police and tactical units, law enforcement agencies and traditional clubs and societies. However, embroidered patches are also a great choice for a clothing and fashion brand who want a more traditional aesthetic for trucker caps, backpacks and denim jackets.
Embroidered Patch Finishing Touches. Overlocked and Heatcut
Please see the woven patch section above with the same heading. The woven patch finishing touch details also apply to embroidered patches.
Embroidered Patch Fixing Application. Sew On, Iron On, Sticky and Velcro Attachment
Please see the woven patch section above with the same heading. The woven patch attachment details also apply to embroidered patches.
What This All Means for Your Embroidered Patches
Embroidered Patches Have Less Details
As we have mentioned, custom made embroidered patches do mean a less detailed design, but this is not always a bad thing. Remember, we are artists here, and we can make creative decisions on the overall look and aesthetic that would be best suited to our needs. The classic embroidered patch has vintage aesthetic, and for brands, businesses or organisations who want to create something that resembles a more militaristic or classic feel, the embroidered patch is the one to go for. They are in fact better for simpler bolder designs with a simple large surface area of colour (or two or three) and a bold outline line to separate colours or to extenuate design details.
Embroidered Patches Cost a Little More
Manufacturing embroidered patches is a little more complex than manufacturing woven patches and they do take a little more time to produce. The extra machine time and man power needed increases the cost, but by roughly 20% only, so we are not talking bank breaking figures here!
Embroidered Patches Are Less Versatile
Although this point is not technically accurate, our custom made embroidered patches can be a little trickier to apply. This is due to the thickness of the patches, because if you remember, we told you embroidered patches are made by embroidering fabric ON TO an existing fabric backing. They are perfectly suited for heavier weighted applications like thick coats (denim, wool, cotton canvas), hats (beanies and snapbacks), bags and military style clothing (which all seem to be made to an extremely high quality with thicker materials).
Conclusion on The Differences Between Woven Patches and Embroidered Patches
Are you still with us on this epic patch journey? If so let’s just quickly conclude the difference between woven patches and embroidered patches.
Custom woven patches are 20% cheaper, they are quicker to manufacture and can hold more detailed designs due to a thinner thread and a weaving manufacturing process.
Custom embroidered patches are a more traditional looking patch, they hold less detail due to thicker threads and a more traditional manufacturing process, but make up for it with a more aesthetically pleasing tactile appearance.
Bonus Patch: Chenille Patches! Or The Caterpillar Patch as We Like to Call Them!
A near 2000-word essay on custom made patches would not be complete without at least mentioning the classic chenille patches! We love these things!
Chenille is the French word for ‘caterpillar’ and it’s the caterpillar’s fur the yarn is supposed to resemble! Did you know caterpillars have fur? Neither did we!
Chenille patches are those fluffy and adorable patches that are usually seen on American style varsity and letterman university baseball jackets. They are Americana Sportswear to the core. They have a huge appeal, and no one can really turn down a chenille patch with your logo or branding on! We are able to manufacture them from sizes 90mm small and up to 500mm! Due to the extremely thick yarn used (crucial for that chenille patch look) we advice keeping these patches simple in appearance with no more than 2 colours as well as using a thicker bold outline if essential.
We have a minimum of 50pc per design on chenille patches with standard turnaround time of an industry beating 28 days. And 18 days for rush orders.
To Conclude This Woven, Embroidered and Chenille Patch Article!
We hope you now understand the main differences in comparing woven patches, embroidered patches and of course chenille patches. If you are still unsure, or have some questions we have not answered, please get in touch and ask away! We love discussing new projects with new and existing clients.
You can contact us HERE!