Keegan G.
Custom Woven Patches
If you want emblems with intricate detail then woven patches are the best choice for your design.
Made on a loom with multiple color threads that can achieve very small detail. These patches add tremendous value to your products and are a great way to promote your business or brand.
Trusted by 1150+ Brands Globally
Custom Woven Patch Shapes
Patch Shapes
Selecting a custom shape is another way to set your woven patches apart from others. Let the shape of the emblem be part of the design and the uniqueness of your patch. But remember if you want to apply it to a hat or bag or sweatshirt keep in mind that sewing a complicated shape or contour can add to the cost or potentially not be possible. So check with one of our friendly customer service representatives to see if your design can be easily applied.
Shield
The classic crest shape for clubs, departments, and team logos.
Circle
Simple, timeless, and works on any hat or beanie cuff.
Square
An even-sided format that suits badge-style logos.
Rectangle
The go-to shape for front-of-hat patches and labels.
Arch
A rounded top that frames scenic and retro designs beautifully.
Diamond
A sharp four-point shape that stands out on hat fronts and jackets.
Oval
A classic shape that takes a merrow border beautifully.
Custom Shape
Your artwork cut to its own outline — complex contours can affect sewing cost, so send us your design and we'll confirm.
Looking for something unique? Our team can source any style or brand to match your exact vision.
Woven 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.
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.
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 & Loop Backing
Two-part backing that lets you swap patches on and off — popular for vests, packs, and uniforms where patches get changed out.
No Backing
We only recommend no backing for labels — woven labels sewn inside hats or clasp labels folded over a beanie cuff.
Woven 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.
Satin Stitch 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.
Specifications
Specs for Ordering Custom Woven Patches
Backing Options
- Iron On
- Paper Back
- Adhesive Back
- Hook & Loop
Production Time
- Sample time 7-8 days. If you require a sample before going into production sample lead time is approximately 8 working days.
- Production time 10 days plus shipping (additional day per 500 pieces).
Emblem Size Limit
- Minimum Size – 1″ X 1″ (+/-1mm)
Color
- 12 thread colors maximum in one design or emblem.
Minimum Text Sizes
- Woven can achieve very small detail. Send over your artwork and we will let you know if it is too small. Most likely it will be okay.
How Woven Patches Are Made
These emblems begin on a special machine called a loom. The loom uses very fine thread, much finer thread than the thread used in embroidery. This fine thread allows the loom to weave your design in very intricate detail. Once the weaving process is complete then the label is given an extra fabric backing for added strength and then a heat seal backing (if requested) by fusing the material to the label. The last step would be a merrow border (another add-on feature) which is added by hand on a special machine by a skilled operator. The result is a beautiful woven patch with your logo or design.
Woven Patches for Beanies
Another great application for woven patches is affixing them onto custom beanies. These style of emblem work well on Beanies because the patches usually need to be small to fit on the cuff of the beanie and with woven detail you can make your design small and still read it perfectly. We recommend heat seal or iron on backing to give the label more stiffness which makes it easier to sew onto the beanie and also gives the label more strength so it doesn't become wavy once applied to your garment.
Custom Woven Patches We Created
Our Work
Explore our custom woven 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 woven patches.
How are woven patches made?
They start on a loom that weaves your design with thread much finer than embroidery thread — that’s what allows the intricate detail. After weaving, the label gets an extra fabric backing for strength, a heat seal backing if requested, and finally a merrow border added by hand by a skilled operator.
What's the difference between woven and embroidered patches?
Detail. Woven patches use smaller threads and can hold distressed textures, super fine lettering, ornate details, even photo-style designs. Embroidered text can’t go below 4mm tall, so if your logo has fine detail, woven is the better choice. Embroidered wins when you want dimensional texture and a classic vintage look.
What backing options do woven patches have?
Iron on, adhesive back, and Hook & Loop. For beanies we recommend heat seal or iron-on backing — it stiffens the label, which makes it easier to sew on and keeps it from going wavy after application.
What size should a woven patch be for hats?
If you want one design to work across dad hats, snapbacks, and truckers, keep it to a maximum of 2.25″ tall by 4″ wide. Not sure? Send us your artwork and we’ll send back a free mockup on your hat style.
Can I order the same design in two colorways?
Yes — if you can’t pick a favorite, run both. Just know that each colorway counts as a separate design because of the setup involved in changing thread colors.
How long does woven patch production take?
Samples take about 8 working days. Production is 10 days plus shipping, with an extra day per 500 pieces.
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!