Question 1

What is PVC?

Accepted Answer

PVC (polyvinyl chloride) is a soft synthetic rubber compound. In patch manufacturing, colored PVC is poured into aluminum molds in layers, starting with the base color and building up to create a finished molded design. The result is a flexible, waterproof, dimensionally precise patch that holds its color and shape through extended field and uniform use.

Question 2

How are custom PVC patches made?

Accepted Answer

Each design gets its own dedicated aluminum mold. Colored soft rubber is poured into the mold in layers — base color first, then each additional color on top — until the design is complete. The mold fee applies once per design and is valid for two years, making reorders straightforward. For more detail on the manufacturing process, see How to Make Your PVC Patch.

Question 3

What is your minimum order quantity?

Accepted Answer

50 pieces. Best pricing starts at 100 pieces.

Question 4

How much do custom PVC patches cost?

Accepted Answer

Pricing is quoted per project based on patch size, number of colors, 2D vs. 3D design, and quantity. A one-time mold fee starting at $75 applies to new designs. As a reference point, a 3-inch, 2-color, 2D patch with sew-on backing starts at approximately $2.12 each at 100 pieces. Request a quote with your design details for exact pricing.

Question 5

How long does production take?

Accepted Answer

The full process from first contact to delivery runs approximately 5–6 weeks:
- Quote and Artwork Layout for Approval: approximately 1 week
- Pre-Production Sample: approximately 1 week
- Full production: approximately 3–4 weeks
Rush options are not available, mention your deadline when requesting a quote and we will do our best to accommodate your requesr.

Question 6

Is PVC flexible?

Accepted Answer

Yes. The soft PVC rubber compound we use is flexible and lightweight. It conforms to curved surfaces — hats, jackets, gear — without cracking or deforming. It is not rigid plastic.

Question 7

What is the standard size for custom patches?

Accepted Answer

- Shoulder patches average 3–4 inches tall.
- Hat patches are typically round, 2–2.5 inches in diameter.
Patches can be made as small as 0.5 inches and as large as 17 inches.
Standard uniform sizes for EMS, police, and fire department applications are 3"x3" and 3"x3.5" for shoulder placement, 3"x2" for hats and flag designs.

Question 8

PVC patch vs. embroidered: which is right for me?

Accepted Answer

Embroidered patches look good when new but degrade with repeated washing and field use: thread frays, colors fade, edges wear. PVC holds up under conditions that destroy embroidery.
Choose PVC if you need:
- Waterproof, heat-resistant, and cold-resistant performance
- 2D or 3D dimensional design
- Sharp reproduction of fine lines, small lettering, or complex insignia
- Consistent color over years of uniform wear
Choose embroidered if you prefer the traditional raised-thread look and texture for dress uniforms or fashion applications.
We produce embroidered patches through our sister site siennapacific.com.

Question 9

Can you convert an existing fabric or embroidered patch to PVC?

Accepted Answer

Yes. Send us your existing patch, a scan, or a reference photo and we'll translate the design into PVC.
We match colors to the Pantone Coated and Uncoated color charts. Specialty color options including Glow in the Dark are also available.
Your department's existing badge or insignia design can be reproduced accurately in 2D or 3D PVC.

Question 10

Do you make patches for hats?

Accepted Answer

Yes. PVC hat patches attach to any hat style — flex fit, snapback, trucker, baseball cap. Standard hat patch size is 2–2.5 inches round. Choose the backing that fits your hat: Hook & Loop for removable placement, iron-on for permanent application, or sew-on for the most secure long-term attachment.

Question 11

How do you apply PVC patches?

Accepted Answer

Hook & Loop: The most common method for uniforms and tactical gear. The hook side is attached to your patch. Sew the loop side onto your garment or gear. The patch attaches and detaches without tools.
Sew-on: Use a needle and thread or sewing machine to stitch around the patch border. Best for permanent placement on uniforms.
Iron-on: Place the patch adhesive-side down on the fabric. Cover with a thin cloth and press with a medium-high iron (no steam) for 15–30 seconds. Hold the iron still (do not move it back and forth). Let the patch cool fully before handling.
Note: iron-on bonding works best on flat fabric surfaces.
For heavy-use uniform applications, sewing over an iron-on patch improves long-term durability.

Custom PVC Patches