Keegan G.
Custom Embroidered Patches
We love custom embroidered patches because you get the high quality feel of direct embroidery on an emblem that can applied onto many different types of apparel.
Custom patches are a cool way to set your business or brand apart from the competition by giving your logo a custom feel with high quality polyester stitching. There are two types of custom embroidered patch: Emblem (with merrow border) or appliqué (custom shape / thin stitch border).
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Custom Embroidered Patch Shapes
Patch Shapes
Embroidered patches can be made in custom shapes and sizes, usually based on your logo and intended use. For hats, keep in mind that most crowns only fit designs around 2"–2.25" tall, with space needed above and below for proper sewing.
Shield
The classic crest shape for clubs, departments, and team logos.
Circle
Simple, timeless, and easy to sew onto any hat or jacket.
Square
An even-sided format that suits badge-style logos.
Rectangle
The go-to shape for front-of-hat patches and name bars.
Arch
A rounded top that frames scenic and retro designs beautifully.
Hexagon
A six sided shape that stands out on hat fronts and jackets.
Oval
A classic emblem shape that takes a merrow border beautifully.
Custom Shape
Your logo cut to its own outline — send us your artwork and we'll shape the emblem to match.
Looking for something unique? Our team can source any style or brand to match your exact vision.
Embroidered Patches Backing Options
Backing Options
Heat seal backing option is great if you want to apply your custom emblem by yourself. We recommend using an industrial heat press if you want it to really adhere to the garment properly but if you are someone who likes to do things yourself that you can try using an iron on patches. If you don't want patches iron on option there is velcro or hook and loop backing. For Hook & Loop backing there is an added charge but being able to affix with hook & loop is a great and versatile backing.
Iron-on Backing
Heat-activated glue attached to the backside of the patches. A simple and easy way to attach patches to clothing and hats.
3M Adhesive Backing
This is a simple sticker for the backside of your patch. A great way to keep the patch in place while sewing onto patch hats.
Hook-and-Loop Backing
Hook & Loop patch backing commonly used with military and airsoft communities. Used to interchange different patches on vests or backpacks.
Embroidery Border Options
Border Options
We take pride in what we do, creating quality pieces for businesses, organizations, and causes of all kinds. We remember what it’s like to be a customer, and understand your time and your money is valuable.
Merrow Border
Thicker stitched-on border. A merrowed edge can be used with standard shapes like squares, rectangles, and circles.
Heat Cut Border
This is an embroidered border with heat-sealed edges to clean up any loose thread. Popular with a more complex shape patch.
Laser-cut Border
A no border option, the laser-cut edge is perfect for extremely detailed shapes and looks fantastic with hook and loop backing.
Name Patches No Minimum
If you are looking for name patches with no minimum we offer stock sizes in 3 different shapes and sizes for this very thing. We offer two types of stock industrial font as well. These name patches can include heat seal backing so that you can iron them on or they can be sewn on. If you have a large manufacturing facility and each employee needs a custom name emblem this is the perfect option for you. We make it easy to order -- just email us an excel spreadsheet with the names listed and we will send you free artwork via a digital mockup for your approval. You can pick the background color of fabric and the stitch color.
Specifications
Specs for Ordering Custom Embroidered Patches
Backing Options
- Low Melt Heat Seal
- Industrial Heat Seal
- Pressure Sensitive
Production Time
- Sample time 7 business days with scan approval via email.
- Production time 10-12 business days plus shipping. Production time begins after scan approval.
- Expedited Rush options available for extra cost.
Emblem Size Limit
- Max – 18″ X 11″ (+/-1mm)
- Min – 1″ X 1″ (+/-1mm)
Color
- The design cannot have more than 15 different colors of thread.
Minimum Text Sizes
- Embroidered text cannot have a height smaller than 4mm and column width of 1mm.
- Embroidered text cannot have a height smaller than 4mm and column width of 1mm.
Custom Embroidered Patches We Created
Popular Styles
Explore our custom embroidered patches, crafted with precision stitching and designed to bring depth, texture, and character to every piece.
Ready to Create Something Custom?
Tell us about your next project — whether it’s custom hats, patches, or branded merch, we’ll help you bring it to life with expert design and production.
Get in TouchFrom Production to Perfect Delivery
Our Simple Process
Our streamlined 5-step process makes it easy to go from idea
to finished product without the usual hassle.
Choose Style
Pick your hat and decoration method.
Send Artwork
Send us your
logo or design.
Get A Free Quote
Receive pricing
& free mockup.
Approve Sample
Confirm your
final design.
Delivery
We produce and ship your order.
Frequently Asked Questions
Everything you need to know about custom embroidered patches
What's the difference between an emblem and an appliqué patch?
An emblem has a merrow border — a thick stitched edge applied by hand after the patch is sewn out, best for simple shapes like circles, ovals, and rectangles. Appliqué has a thin border stitch following the contour of the design, which works better for complex custom shapes.
What do 100%, 75%, and 50% embroidery mean?
That’s how much of the patch surface is covered in stitching. 100% means fully stitched. At 75%, a quarter of the background twill fabric shows through; at 50%, half does. Our pricing is the same no matter how much stitch coverage you choose.
What backing options are available for embroidered patches?
Low melt heat seal, industrial heat seal, and pressure sensitive backing. Heat seal lets you apply patches yourself with a heat press or iron, though for hats and jackets we always recommend sewing for a permanent hold. Velcro (hook & loop) backing is also available for an added charge.
What size patch fits on a hat?
Most hat crowns allow a design about 2″ to 2.25″ tall — there needs to be room above and below the patch for it to be sewn on correctly. Overall we can produce patches from 1″ x 1″ up to 18″ x 11″.
How small can embroidered text be?
Text needs to be at least 4mm tall with a 1mm column width. If your logo has finer lettering than that, a woven patch will hold the detail better.
How long do embroidered patches take?
Sample time is 7 business days with scan approval by email. Production is 10–12 business days plus shipping after you approve the scan. Rush options are available for an extra cost.
Built on Trust, Quality, and Speed
Why Choose Consolidated Ink
We deliver retail-quality custom products with precise embroidery, structured fits, and reliable production.
Low Minimum Orders
Order as low as 24 hats per design. Perfect for small teams or test runs.
Free Design Support
Send a logo or idea, we refine, digitize, and mock it up at no cost.
Fast Turnaround
Most orders are shipped within 2–3 weeks, with rush options available.
Discounts on Bulk Orders
Tiered discounts that make larger orders more cost-effective.
Retail-Grade Quality
Premium brands, finished with high-quality embroidery, patches, and prints.
Satisfaction Guaranteed
If something’s off, we fix it.
Simple as that.
5.0 Star Reviews on Google
Hear first-hand from our incredible community of customers.
I have had countless orders with Consolidated over the last 10+ years. Hats, hoodies, shirts, embroidery... the attention to detail is something I never have to question, and my recent order of 144 t-shirts was no different. I didnt even need to check the print before I put the order in the back of the truck. Thank you guys.
Consolidated Ink was such a pleasure to work with! Professional, punctual and extremely communicative. Not only was all the design and printing Perfect, but the materials they recommended were great quality. I have already placed a full re-order with them. Highly recommend using Consolidated Ink.
Could not be happier. Needed a small quantity of T-shirts for an important public event -- and fast! Not only was the whole job turned around on a dime, but the result was terrific -- and they actually improved the main graphic, generating a higher resolution version. Never going anywhere else.
We used consolidated ink to curate our swag for the local little league… our merch is the talk of the town and sought out by many! Coolest hats and softest t-shirts around. We even had a tight deadline and they came through for us!
The team at Consolidated Ink did such a great job. They turned around merchandise for us in such a fast manner - even got great delivery and complete quality were so thrilled with results thank you thank you
Would highly recommend anyone work w Consolidated Ink - incredibly detailed, professional & reasonably priced. Pat was able to source exactly what I needed and got the job done within days of placing the order. 5 stars!