If you're ordering patches for gear, uniforms or merchandise, you'll quickly face a choice: PVC or embroidered? Both are excellent, but they shine in different situations.
What is a PVC patch?
PVC patches are made from soft, flexible polyvinyl chloride. Liquid PVC is poured color by color into a custom metal mold and heat-cured. The result is a rubbery patch with sharp raised edges, bright solid colors and no thread at all.
What is an embroidered patch?
Embroidered patches are stitched with polyester or rayon thread onto a twill base. They have a raised, textured surface and the traditional look most people picture when they think of patches.
Durability and weather resistance
PVC wins in wet and dirty conditions. It doesn't absorb water, wipes clean, and resists sun fading. That's why PVC is popular for search and rescue teams, boaters, anglers, outdoor brands and tactical gear.
Embroidered patches are durable too — polyester thread is colorfast and holds up to frequent laundering — but they will absorb water and can collect dirt in the stitches.
Detail and small text
PVC molds hold fine lines and small text better than thread, as long as raised details are at least about a millimeter wide. Embroidery is best with bold shapes and lettering roughly 1/4 inch tall or larger.
Look and feel
This is mostly about style:
- PVC looks modern, graphic and rugged — great for cartoons, mascots and tactical designs.
- Embroidery looks classic and handcrafted — ideal for uniforms, clubs and heritage brands.
Attachment options
PVC patches are usually finished with hook-and-loop or sew-on backing. They cannot be ironed on, because heat deforms PVC. Embroidered patches support every backing, including iron-on.
Cost
PVC requires a one-time mold fee for each new design, which is reused on reorders. Embroidery requires digitizing instead. For small quantities, embroidery is often more economical; as quantities grow, PVC becomes very competitive because the mold cost is spread across more patches.
Quick recommendations
- Morale patches and tactical gear: PVC with hook backing
- Uniform shoulder patches: embroidered or woven, sew-on
- Outdoor brand hats: PVC or leather
- Club and team jackets: embroidered or chenille
- Patches for boats and wet gear: PVC
Can I order both?
Absolutely. Many teams order a PVC version for gear and an embroidered version for jackets or keepsakes from the same design. We keep both files on record for easy reorders.
Ready to compare prices? Request a free quote and mention both options — we'll price them side by side. Learn more about PVC patches and embroidered patches.