Choosing between embroidered and woven patches is really a question about detail. Embroidery uses thicker thread stitched onto twill, producing a raised, textured finish with bold colour blocks. Weaving uses finer thread at much higher density, producing a flat surface that can render small text and gradients. If your design has lettering under 4 mm, weaving wins. If it is a bold badge, embroidery looks better and costs less.

Key Differences

• Thread: embroidery uses standard rayon or polyester thread; weaving uses fine polyester at roughly double the stitch density
• Surface: embroidery raised and textured; woven flat and smooth
• Small text: embroidery struggles below 4–5 mm; woven renders cleanly down to 2 mm
• Gradients: impossible in embroidery; achievable in woven through thread blending
• Thickness: embroidery adds bulk; woven patches lie flat under a garment
• Cost: woven typically 10–20% above embroidered at the same size

Choose Embroidered When

Your logo is bold with solid colour areas, you want the classic raised look, the patch will be seen from a distance, and budget per unit matters. Varsity letters, club badges, mascot designs and most uniform patches fall here.

Choose Woven When

Your design contains fine text, thin lines, gradients or photographic elements. Woven is also the better choice for patches on performance fabrics and caps where bulk would look wrong, and for brand guidelines that specify exact small-type reproduction.

Backing and Border Options Apply to Both

Iron-on, Velcro hook-and-loop, adhesive, plastic backing and sew-on are available on both types. Merrowed overlock borders suit simple shapes; laser-cut heat-sealed edges suit complex outlines and prevent fraying.

See our full custom patch range, or start small through our no minimum patch programme.

Frequently Asked Questions

Can woven patches do 3D puff?

No. 3D puff foam requires embroidery. Woven is inherently flat.

Which is more durable?

Both last for years. Embroidery is more abrasion resistant because of thread thickness; woven resists fraying because the edge is heat sealed.

What is the minimum size?

1.5 inch for embroidery, 1 inch for woven.

Can I get both to compare?

Yes. We produce a sample of each so you can compare against the actual garment before committing.

How much does woven cost?

Roughly 10–20% above embroidered. Request an itemised quote on our patch pricing page.