7-Day Turnaround for Shin Ku Karate Uniform Patches
Shin Ku Karate in Leander, Texas needed 100 uniform patches for an upcoming class, but their previous supplier couldn’t hit the deadline.
We engineered a 3-inch, high-density embroidered patch with a heavy merrowed border and industrial heat seal backing, delivering the full order in exactly 7 days.
Project Gallery
We don’t use stock photos. Here is what came off our line this week for SHIN KU KARATE.
Production SnapshotClient Overview
The Challenge
The Timeline
The previous supplier flaked. Shin Ku needed these patches in hand in one week. In the custom embroidery world, standard turnaround is usually 14 days. We had to cut that in half without skipping quality control.
Quality Concerns
The client’s old patches looked “fuzzy.” The text wasn’t sharp, and the edges frayed after a few cycles in the washing machine. When you run a dojo, having students wear tatty uniforms looks unprofessional.
Adhesion on Heavy Canvas
They requested Iron-On backing. The problem? Gi fabric is thick. Getting heat to penetrate through the patch and the thick canvas to melt the glue requires industrial-grade adhesive, not hobby store glue.
Patch Specifications
To solve these problems, we locked in these specs:
Custom Embroidered
100% thread coverage.
3 Inches
Standard chest/shoulder size.
Industrial Heat Seal
Iron-On adhesive.
Merrowed Edge
This is critical. A laser-cut edge will fray on a Gi. A merrowed edge wraps the fabric, creating a “bumper” that protects the patch during sparring.
100 Pieces
Our Process: The 7-Day Sprint
Here is how we moved this order through the shop in one week.
Artwork & Adhesives
We received the logo. Because the design included Kanji (Japanese characters), we had to adjust the stitch density. If stitches are too tight on small text, they bunch up. We opened up the spacing slightly to ensure the characters remained readable. We also selected our High-Temp bonding film designed for heavy cotton/poly blends.
Production
Weaving: We ran the patches on our Tajima heads.
Merrowing: We ran every patch through the overlock machine to seal the edges.
Inspection: We checked for “thread breaks” (where the machine misses a stitch). In martial arts, a loose thread becomes a snag hazard.
Delivery
Packed, sealed, and shipped directly to Leander, TX.
Factory Insight The “Gi” Washing Rule
We bonded these with Iron-On backing as requested, but I gave the client a piece of advice I’ll give you too: Iron-On is for placement; Sewing is for permanence. On a Karate Gi, the friction from grappling will eventually peel any glue. I always recommend ironing the patch to get it centered, and then running a single stitch line around the edge to lock it down forever.
The Result
We delivered the 100-piece order on time, and the difference in quality was immediate.
The detail was sharper than our old supplier, especially on the lettering. We ironed them on right before class, and they didn’t peel up at the corners during warm-ups.
Clean Application
The industrial adhesive melted evenly into the heavy weave of the uniform fabric without oozing out the sides.
No Fraying
The Merrowed border did its job. Even after the first wash cycle, the edges remained tight and sealed.
Legibility
The adjusted stitch density meant the Japanese Kanji characters were crisp and readable, not blobby.
Need Patches Like These?
If you run a dojo or academy in Texas and need uniform patches that don’t fall apart, here is the exact recipe we used for Shin Ku:
- Type: 100% Embroidered Patch
- Size: 3.0 Inches
- Backing: Iron-On (Heat Seal)
- Border: Merrowed (Essential for durability)
Frequently Asked Questions
Common questions about durability, washing, and production speed for martial arts patches.
DurabilityHow durable are iron-on karate patches?
How durable are iron-on karate patches?
They are durable for striking arts (Karate, Tae Kwon Do). However, for grappling arts (BJJ, Judo), we highly recommend sewing them on. The friction of the mat and grabbing the lapel will eventually pull any glue loose.
CareCan merrow borders survive frequent washing?
Can merrow borders survive frequent washing?
Yes. That is exactly what they are designed for. The overlock stitch prevents the fabric from unraveling in the washer. We recommend washing uniforms inside out to extend the life of the patch.
TurnaroundWhat is the fastest turnaround for 100 pcs?
What is the fastest turnaround for 100 pcs?
We can typically turn around an order of 100 embroidered patches in 7–10 business days. If you have a belt ceremony or tournament deadline, let us know upfront so we can schedule the machines.
DesignDo you digitize martial arts logos?
Do you digitize martial arts logos?
Yes. We specialize in cleaning up complex crests, dragons, tigers, and Kanji text so they stitch out cleanly.
SpecsCan you match existing uniform colors?
Can you match existing uniform colors?
Yes. If you send us a photo or a physical sample of your belt or uniform trim, we will match the thread color to ensure your branding is consistent.