Custom Woven Patches
Precision Weave TechnologyEmbroidery turns small text into a messy blob. We weave your design into the fabric using micro-threads for absolute precision. The San Antonio Patch Co. factory standard for JBSA name tapes and complex corporate logos.
What Is The Difference? (Woven vs. Embroidery)
Embroidery
- Embroidery has noticeable texture and height.
- Offers a classic, traditional “3D” thread feel.
- Struggles with fine lines and small details.
- Thicker and heavier on the garment.
Woven Patches
- The weave is tight and gapless.
- Feels smooth, like a high-quality clothing label.
- Perfect for high-definition clarity.
- Thin, flexible, and lightweight.
Why Our Clients Switch Embroidered to Woven Patches
We recommend woven patches for these three specific situations:
Small Text is Critical
If your design includes a phone number, website, or motto under 4mm tall, woven is the only way to make it legible.
Performance Wear
Woven patches are thin and lightweight. They won’t weigh down moisture-wicking shirts or create a stiff “shield” on the chest like heavy embroidery does.
High Volume, Low Cost
Woven patches use less material bulk, making them a budget-friendly option for large orders (like trade show giveaways or 500+ unit runs).
Backing Options For Woven Patches
The manufacturing is only half the battle; choosing the right backing gets the patch onto the gear.
Sew-On (The Standard)
This is the default. We provide the patch with a stable backing. You (or a tailor) sew it directly onto the garment. It’s permanent and bombproof.
Iron-On (Heat Seal)
We apply a heat-activated adhesive to the back. You can apply these with a home iron or a heat press (300°F for 15 seconds). Great for hats and t-shirts.
Velcro® (Hook & Loop)
The “Hook” side is sewn to the patch, and we send you the matching “Loop” piece. Standard for tactical caps and military gear.
Peel & Stick
A temporary sticker backing. Only use this for one-day events or VIP passes.
Choose The Right Border for Woven Patches
The edge of your patch matters more than you think. (See our Full Border Guide).
Merrowed Border
This is the thick, raised thread border you see on most round or square patches. It protects the edge from fraying and looks traditional.
Best For: Simple Shapes (Circles, Squares)
Laser Cut Edge
If your patch has a weird shape (like a jagged lightning bolt or a cutout), we use a laser to cut it out. The heat seals the threads instantly. Use this for complex custom shapes.
Best For: Complex Custom ShapesHow We Price Your Woven Patches
We keep our pricing simple. You aren’t paying for “setup fees” or hidden surcharges. You’re paying for the patch and the shipping.
What Moves the Needle
- Size We use a standard formula. A 3×3 patch is priced as a 3-inch patch.
(Length + Width) / 2 - Backing Choice Sew-on is standard. Adding Iron-on, Velcro, or Peel-and-Stick adds a few cents per patch.
- Color Count Woven patches can handle up to 12 colors. Unless you have a crazy complex design, the number of colors usually doesn’t change the price.
Quantity: The Biggest Factor
Setting up the loom takes time, whether we run 10 patches or 10,000. The more you order, the cheaper the unit price gets.
Production & Turnaround
Proofing
You’ll get a digital proof within 24 hours. We don’t weave a single thread until you say “Go.”
Production
Once approved, it takes about 10–14 days to weave, cut, and inspect your order for perfection.
Shipping
We ship directly from our facility. If you are local to San Antonio or the JBSA area, delivery is fast.
“Whether you need a small run for a single squad or thousands for a corporate rebrand, the quality remains the same.”
Woven vs. Embroidered: Which One Do You Need?
This is the most common question we get. Here is the honest breakdown so you don’t buy the wrong product.
Choose Woven If:
-
You have small text
If your design has phone numbers, intricate mottos, or tiny lettering (under 4mm), woven is the only way to make it readable.
-
You want a flat profile
Woven patches are thin and light. They lay flat on performance shirts and won’t weigh down the fabric.
-
You have a complex image
Gradients, landscapes, and detailed faces look like photos on a woven patch.
Choose Embroidered If:
-
You want texture
Nothing beats the classic, raised 3D feel of embroidery. It feels expensive and heavy.
-
Your design is bold
Simple logos with thick lines look great embroidered.
-
It’s for a uniform
Many official uniforms (Police, Fire, Military Dress) specifically require the traditional embroidered look.
Go Embroidered
If you need your logo to be recognizable from 5 feet away, go Embroidered. The texture catches the light and stands out.
Go Woven
If your patch is meant to be read up close (like a name tape or a safety label), go Woven. The flat surface makes the text crisp and easy to read at arm’s length.
Why San Antonio Patch Co.?
We are a factory-direct operation. That means when you call us, you aren’t talking to a call center overseas; you’re talking to people who know the difference between a Merrowed edge and a Laser Cut edge.
Direct
We Check Every Patch
We don’t just dump them in a box. We check the edges, the backing, and the text clarity.
Local Focus
We understand the needs of our local clients, from the durability required for oil field workwear to the specific regulations for JBSA uniforms.
No Nonsense
If your design won’t work as a woven patch, we will tell you and suggest a better alternative (like PVC or Print).
The Ordering Process
We stripped out the complicated steps. Here is how it works:
Send Your Art Work
Upload your logo (Vector is best, but we can work with JPEGs). Tell us the size and how many you need.
Approve the Proof
We will email you a mock-up. Check the spelling, colors, and size. We don’t start the looms until you say “Go.”
Production
We weave, cut, and back your patches using our high-definition looms.
Get Your Custom Woven Patch Quote
Upload your artwork and receive your free digital proof. Your logo deserves a stitch-perfect finish.
- Free digitizing
- Free shipping
- 100% quality guarantee
Frequently Asked Questions
Everything you need to know about ordering custom woven patches.
DurabilityAre woven patches as durable as embroidered ones?
Are woven patches as durable as embroidered ones?
Yes. They are made from polyester thread, which is resistant to fading, water, and heat. Because the weave is so tight, they are actually less likely to snag on sharp objects than embroidered patches.
Care InstructionsCan I wash woven patches?
Can I wash woven patches?
Absolutely. They handle standard wash cycles just fine. If you use Iron-on backing, we recommend washing in cold water or sewing the corners down for extra security.
Detail & TextWhat is the smallest text I can use?
What is the smallest text I can use?
We can weave text as small as 2mm and keep it legible.
Special ThreadsDo you offer metallic threads?
Do you offer metallic threads?
Yes, we can weave gold or silver metallic threads into the design for a premium look.
SamplingCan I get a sample before ordering the full batch?
Can I get a sample before ordering the full batch?
For most orders, the “digital proof” is enough. If you need a physical sample in your hands before running a large bulk order, let us know, and we can arrange a pre-production sample (this adds time to the process).
ShippingDo you ship to APO/FPO addresses?
Do you ship to APO/FPO addresses?
Yes. We support our military clients and ship to bases worldwide.