Custom Embroidered Patches San Antonio
In a city known for its high standards and military heritage, San Antonio Patch Co. embroidered patches provide the durability and classic look San Antonio professionals rely on. These patches are built for daily wear and the South Texas heat, ensuring your logo stays sharp and colorful through every wash cycle.
Why Choose Embroidered Over Other Types
Embroidered patches use raised thread to create a true 3D surface you can see and feel.
This dimensional texture delivers a premium, traditional look that flat printing simply cannot match.
Embroidered vs Woven
Better texture, stronger visual depth, and a more traditional appearance than the flat weave of woven labels.
Embroidered vs PVC
Heat resistant, fabric-based, and more professional for uniforms compared to rubberized plastic.
Embroidered vs Sublimated
Unmatched durability and superior wash resistance. Ink fades; thread lasts.
Custom Embroidery Coverage Levels
Coverage controls how much of the base 300D Twill fabric is visible vs. covered by thread.
50% Coverage (Minimalist)
The design sits on exposed twill. Lightweight and economical for simple designs.
75% Coverage (Standard)
The design covers most of the background. Balanced appearance and durability.
100% Coverage (Premium)
Full stitch fill edge-to-edge. No twill visible. Maximum premium texture.
100% coverage is what you choose for police, fire, and executive uniforms, it feels substantial in the hand and looks the most “official” when worn.
Higher coverage increases stitch count, which directly impacts cost, thickness, and long-term durability.
Custom Patch Border Options
Choosing the correct border is not cosmetic, it directly affects lifespan, attachment reliability, and overall user experience.
Merrowed Border
The most common and durable option. A thick overlocked thread wraps around the edge of the patch, sealing it and preventing fraying.
Best For: Classic Shapes
Laser Cut Border
Uses heat to cut the patch exactly to the shape of the design. Ideal for complex silhouettes where a merrowed edge would distort the artwork.
Best For: Complex Silhouettes
Hot Cut Border
Mechanically sealed for thicker fabrics that require stronger edge bonding. Provides a clean, sharp edge profile.
Best For: Thicker FabricsEmbroidered Patches Backing Options
Iron-On (Heat Seal)
Best for cotton & polyester caps and garments. Heat activated bond. Permanent bond for denim and cotton.
Velcro (Hook & Loop)
Essential for tactical & military use. Interchangeable. Standard for San Antonio military personnel and first responders.
Adhesive (Peel & Stick)
Temporary sticker backing for events & promotions.
Sew-On (Permanent)
Most permanent and durable attachment method.
Transparent Bulk Pricing for San Antonio
Need a small batch? We offer no-minimum ordering starting at just 10 patches. For larger projects, see our bulk savings below:
| Patch Size | 50 Units | 100 Units | 250 Units BEST VALUE |
|---|---|---|---|
| 2.5″ Small | $3.50 ea | $2.10 ea | $1.45 ea |
| 3.0″ Standard | $4.25 ea | $2.65 ea | $1.85 ea |
| 3.5″ Large | $4.95 ea | $3.15 ea | $2.25 ea |
The Manufacturing & Ordering Process
Digitizing & Stitch Engineering
Your artwork is converted into a DST embroidery file.
Every stitch path is engineered for strength, clarity, and long-term performance.
Digital Proofing
You receive a full proof showing exact needle placement before production begins.
Nothing is stitched until you approve it.
Production & Quality Control
Patches are produced on industrial Tajima & Barudan machines for consistency across thousands of units.
Each batch is inspected for stitch density, color accuracy, and edge integrity.
Embroidered Patch Construction & Materials
Thread Selection
High-Shine Rayon Thread
High shine, rich colors. (See Color Charts). Best for fashion.
Heavy-Duty Polyester Thread
Matte finish, bleach resistant. Best for uniforms.
The Foundation | Why 300D Twill Matters
- Dense woven structure
- Holds stitches firmly
- Resists fraying and distortion
- Maintains shape through years of wear
Pricing & Turnaround – The Cost Deep Dive
What Affects Price
- Stitch count Complexity of your design directly impacts machine time.
- Patch size (Length + Width) ÷ 2
- Total quantity ordered Volume is the biggest lever for price reduction.
Why Higher Quantities Cost Less Per Patch
Setup costs remain fixed. When you order more patches, those setup costs are spread across each unit, significantly reducing your price per patch.
Standard Production (10-14 Days)
10-14 DaysRush Production (7 Days)
7 DaysDurability & Performance
Laundering & Wash Resistance
- Safe for commercial washing
- Survives industrial dryers
UV Exposure & Fade Resistance
- Polyester thread is colorfast
- Resists fading under sun exposure
Abrasion & Wear Tolerance
- Dense stitching protects base fabric
- Top choice for workwear & gear
Frequently Asked Questions
Everything you need to know about ordering custom embroidered patches.
CostHow much do custom embroidered patches typically cost?
How much do custom embroidered patches typically cost?
Pricing depends on size, quantity, and stitch count, but bulk orders generally start as low as $0.45 per patch with no hidden setup fees.
Ordering ProcessHow do I order embroidered patches?
How do I order embroidered patches?
Simply upload your artwork for a free digital proof; once you approve the stitch-perfect design, we move straight into production and delivery.
Minimum OrderWhat is the minimum order?
What is the minimum order?
We offer no-minimum ordering starting at just 10 patches, making us perfect for both small local projects and large-scale industrial needs.
Patch TypesWhat are the different types of custom patches?
What are the different types of custom patches?
We offer traditional embroidered, low-profile woven, durable PVC, and high-detail sublimated patches to suit any uniform or brand style.
MaterialsWhat materials are used for high-quality patches?
What materials are used for high-quality patches?
We use high-tensile polyester or rayon thread on industrial-grade 300D twill to ensure maximum resistance to heat, fading, and fraying.
Turnaround TimeWhat is the typical turnaround time for an order?
What is the typical turnaround time for an order?
Standard production takes 12-14 business days, but we offer rush production options for tight deadlines or upcoming events.
Embroidery CoverageWhat’s the difference between 75% and 100% embroidery?
What’s the difference between 75% and 100% embroidery?
75% coverage shows some of the background twill fabric, while 100% is a "full stitch" fill where every millimeter is covered in thread for a premium, heavy-duty feel.
ThreadCan I use metallic or glow-in-the-dark thread?
Can I use metallic or glow-in-the-dark thread?
Yes, specialty threads are available. Upon request, we can incorporate metallic gold/silver or glow-in-the-dark threads to add unique visual impact to your design.
Get Your Custom Embroidered 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
