Commercial Methods Used by Professional Shops

If you’ve ever wondered how embroidery patches are made, the answer depends on the patch style and the equipment being used.

In commercial embroidery environments, patches are produced using specialized digitizing techniques and professional production methods — all run on commercial embroidery machines.

At TheEmbroideryWarehouse, we provide the commercial machines and supplies needed to produce professional-quality patches in-house.

Here’s how patches are typically made.

Traditional Embroidered Patches (Full Stitch)

This is the most common patch style.

The design is stitched directly onto twill or patch fabric using a commercial embroidery machine. The embroidery often fully covers the base material, creating a dense, textured finish.

After stitching, the patch is:

  • Laser cut
  • Die cut
  • Or trimmed manually

These patches can then be finished with:

  • Heat seal backing
  • Velcro backing
  • Traditional sew-on backing

Any properly digitized commercial embroidery machine can produce traditional embroidered patches.

Merrowed Edge Patches

Merrowed patches feature a thick, overlock stitched border around the edge — commonly seen on military-style patches.

Production process:

  • Embroider the patch design
  • Trim the patch to shape
  • Run it through a merrow machine to apply the stitched edge

The embroidery machine creates the design. The merrow machine finishes the border.

Satin Stitch Border Patches

Instead of using a separate merrow machine, some shops create the border directly on the embroidery machine using a dense satin stitch.

This method:

  • Allows custom shapes
  • Creates a clean, modern edge
  • Eliminates the need for additional equipment

It’s a popular method for modern patch production and short-run customization.

3D Puff Patches

Raised patches can be produced using 3D puff foam placed under specific design elements. This creates dimension and texture before trimming and finishing.

Commercial embroidery machines handle puff patches the same way they handle standard puff embroidery — success depends on proper digitizing and setup.

Velcro-Backed Patches

For tactical, military, and uniform applications, patches are often stitched and then sewn onto Velcro backing.

These are common for:

  • Law enforcement
  • Military units
  • Corporate uniforms
  • Clubs and organizations

What Machines Are Used to Make Patches?

Professional embroidery patches are produced on commercial embroidery machines such as:

Single-head machines work well for custom orders and short runs. Multi-head machines are ideal for high-volume patch production.

Everything You Need for Patch Production

At TheEmbroideryWarehouse, we supply:

  • Commercial embroidery machines
  • Patch backing materials
  • Twill fabric
  • Stabilizers
  • Needles and thread
  • Replacement parts

If you want to start producing patches in-house, we can help you select the right equipment and materials for your production goals.

Start Making Embroidery Patches the Right Way

Patches are one of the most profitable segments in commercial embroidery. With the right machine and materials, you can produce custom patches for uniforms, clubs, retail brands, and organizations.

If you’re ready to add patch production to your embroidery business, contact TheEmbroideryWarehouse today.

We provide everything you need to do it right.