9 Key Factors That Influence Custom Patch Cost

Patches are becoming more popular than ever. Whether used for branding, team identity, or fashion statement pieces, custom patches offer a durable and eye-catching way of conveying a message.

But one of the first questions people ask when considering custom patches is: how much do custom patches cost? The answer varies. Several important factors influence the final price. Understanding these key custom patch cost influencers can help you make informed decisions – and stay within budget.

Factors That Impact Custom Patch Cost

The cost of custom patches depends on multiple variables. Here’s a detailed breakdown of some of the important ones.

1. Patch Size and Shape

One of the most influential factors that impacts patch pricing is its size. Patch manufacturers usually calculate prices based on the average of the width and height. Generally, the larger the patch, the higher the cost. That’s because bigger patches require more materials, stitching, and production time than standard patch sizes, which directly increases expenses.

Besides patch size, shape also plays an important role in the cost. Irregular-shaped custom patches cost more than standard circular, square, or rectangular ones. That’s because unique-shape patches often require additional production steps, increasing both time and labor involved.

2. Quantity

The number of patches you order plays a significant role in determining the cost per piece. Due to economies of scale, typically, the larger the order, the cheaper the price per patch becomes. While a single patch might cost several dollars to produce, ordering 100 or 500 units could significantly reduce the cost per unit.

But besides this, many patch manufacturers also offer tiered pricing structures, where unit prices drop the greater the volume. This is because setup and digitization costs are spread across more units, making production more efficient. If you’re looking for the best value, ordering in bulk often yields substantial savings.

3. Level of Design Complexity

Source: Freepik

The design of your patch affects pricing more than you think. A simple design with fewer thread colors and minimal detail is quicker and cheaper to produce than a complex logo with fine lines, small lettering, or detailed shading. That’s because the latter requires more effort, a higher thread count, and longer production time.

4. Color Count

Most patch manufacturers offer a certain number of thread colors included in their base price. If your design exceeds this limit, you’ll most likely have to pay additional charges. This is because each color change in the process requires machine adjustments and can slow down production.

Moreover, some special colors, such as metallic threads or glow-in-the-dark threads, are considered premium materials and are priced higher than standard threads. While these threads add a visual flair and uniqueness to your patch, it also means you can expect a considerable jump in the overall price.

5. Backing Type

The backing of a patch will determine how it’s applied, but it can significantly impact the final cost as well. Iron-on patches can be applied using heat. It’s a convenient option, but sometimes the cost is slightly higher than the other types of patches because of the heat-sensitive adhesive layer.

Also, if you consider Velcro backing, which are ideal for military, tactical, or temporary uses, you will note that Velcro adds versatility, but it also adds to the cost due to the hook-and-loop component. Then there are patches with double–layer felt. Double-layer felt backing provides extra thickness to a patch. The double layer of felt typically adds to the price tag since additional material is used.

The backing you choose depends on how the patch will be used. More functional and durable backings usually come with a higher cost.

6. Border Type

Patch borders are typically either merrowed or heat-cut, and the choice can impact both the appearance and cost.

Merrowed borders are thick, raised edges sewn around the patch, best for standard shapes like circles or rectangles. They’re durable and traditional but not suited for irregular shapes.

Heat-cut borders, also known as laser-cut borders, are often used for custom, irregular shapes. Since these require more precision and technology, the cost is usually slightly higher.

The price difference may not be extreme, but for larger orders or unusually shaped patches, the border choice can affect both appearance and overall cost.

7. Digitizing Fees

Source: Freepik

Before a patch can be manufactured, designs must be digitized and converted into a digital file that machines can read. Many suppliers charge a one-time digitizing fee based on the design’s complexity and size. Some vendors include it in the overall pricing, while others bill it separately. Although it’s a one-time cost (you won’t pay it again if you reorder the same design), it’s an important upfront factor that can add to your initial expenses.

8. Turnaround Time

If you need your custom patches quickly, be prepared to pay a premium. Rush orders often involve expedited production, priority scheduling, and overnight shipping – all of which increase costs. On the other hand, standard turnaround times come with standard pricing – making it a more budget-friendly option. That’s right, planning ahead and allowing for standard production time is a great way to save money.

9. Shipping

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Shipping costs also contribute to the total custom patches price. Heavy, large, or international shipments can lead to significant additional charges. Some patch makers offer free shipping within certain countries or on bulk orders, while others include shipping as a separate line item.

Final Thoughts

As you can see, custom patch cost is influenced by several key factors – from design and size to materials and turnaround time. While it’s tempting to focus solely on getting the cheapest price, it’s equally important to consider durability, quality, and purpose. If a patch is going to be worn often, displayed prominently, or used in branding, investing in quality materials and craftsmanship is well worth the cost.

And that’s why you need Anything Chenille. We help balance budget and quality so you can get custom patches that reflect your vision and stand the test of time. Talk to one of our company representatives to discuss your customization needs. Remember, order in bulk to get the best value.