Custom Iron On Patches operates a full set of commercial patch manufacturing equipment at its Birmingham workshop. The facility houses multi-head embroidery machines, narrow-loom weaving equipment, silicone PVC moulding stations, dye-sublimation printers, chenille chain-stitch machines and laser cutting systems. Every patch type sold by the company is produced on this equipment in the UK.
This page lists the production equipment and explains what each machine produces.
Embroidery Equipment
The embroidery floor uses commercial multi-head embroidery machines for high-volume production. Multi-head machines stitch the same design simultaneously across multiple patches, increasing throughput without sacrificing detail.
Capability:
| Specification | Detail |
| Machine type | Commercial multi-head embroidery machine |
| Heads per machine | 6, 12 or 20 |
| Maximum stitch count per patch | Up to 25,000 stitches |
| Minimum patch size | 25mm (1 inch) |
| Maximum patch size | 300mm (12 inches) |
| Thread types | Polyester, rayon, metallic |
| Thread colour range | Pantone-matched, full colour range |
The embroidery machines produce three styles of embroidered patch:
- Flat embroidered patches – standard two-dimensional embroidery on twill, felt or polyester base fabric
- 3D puff embroidered patches – raised embroidery using foam underlay, used for varsity and team patches
- Appliqué patches – embroidery combined with fabric inset to reduce stitch count on large designs
For a full description of the embroidery process, see how we make patches at the workshop.
Weaving Equipment
Woven patches are produced on narrow-loom weaving machines. Weaving achieves higher detail than embroidery on small patches because the thread itself forms the design rather than being stitched onto a base fabric.
Capability:
| Specification | Detail |
| Machine type | Narrow-loom weaving machine |
| Thread material | Fine polyester |
| Detail resolution | Higher than embroidery on small patches |
| Minimum patch size | 15mm (0.6 inches) |
| Texture | Smooth, flat finish |
| Best use | Logos with fine text, gradients, complex small designs |
Weaving suits corporate logos with fine text, fashion-brand patches and small detailed designs that would lose definition in embroidery.
PVC Moulding Equipment
PVC patches are produced using silicone moulds and liquid PVC compound. The moulding station handles 2D and 3D PVC patches in any shape.
Capability:
| Specification | Detail |
| Process | Silicone mould + liquid PVC compound |
| Patch dimensions | 2D (flat) or 3D (raised) |
| Maximum thickness | Up to 5mm for 3D patches |
| Backing options | Iron-on, sew-on, hook-and-loop, plain |
| Weather resistance | UV-stable, waterproof, heat-resistant |
| Best use | Outdoor wear, military and morale patches, branded merchandise |
PVC patches suit applications where embroidery would degrade, rain gear, tactical equipment, outdoor uniforms and high-wear environments. Each PVC patch is hand-finished after moulding.
Print Equipment
Printed patches are produced using dye-sublimation and digital printing equipment. Printing reproduces photo-realistic and full-colour designs that embroidery and weaving cannot.
Capability:
| Specification | Detail |
| Process | Dye-sublimation onto polyester base |
| Colour reproduction | Full CMYK + Pantone matching |
| Resolution | Photo-realistic |
| Maximum patch size | 300mm |
| Best use | Photo-based designs, gradient artwork, complex full-colour logos |
Sublimation printing bonds the ink directly into the polyester fibre, producing patches that resist fading and washing. Printed patches suit fashion brands, complex full-colour designs and any artwork featuring photographs or smooth gradients.
Chenille Equipment
Chenille patches are produced on chain-stitch chenille machines. Chenille creates a soft, raised, tufted texture using thicker yarn, the traditional finish of varsity letters and letterman jackets.
Capability:
| Specification | Detail |
| Process | Chain-stitch chenille machine |
| Texture | Soft, tufted, raised |
| Base fabric | Felt |
| Best use | Varsity and letterman patches, school and university crests, sports club patches |
Chenille production sits in its own zone of the workshop. The technique is slower than embroidery but produces a finish no other patch type matches.
Border Finishing Equipment
Every patch receives one of four border finishes. Each finish requires specific equipment.
| Border Type | Equipment | Best For |
| Merrow border | Merrow stitching machine | Traditional embroidered patches with raised edge |
| Laser-cut edge | Commercial laser cutter | Patches with intricate or non-standard shapes |
| Hot-cut edge | Hot-knife cutter | Standard rectangular and circular patches |
| Hand-cut edge | Manual finishing | Specialist or short-run patches |
Border choice affects both appearance and durability. The team recommends a border type based on the patch shape, base fabric and end use.
Backing Application Equipment
Every patch type can be supplied with one of five backings. Backing is applied at the workshop using heat-seal presses and adhesive application equipment.
| Backing Type | Application | Best For |
| Iron-on backing | Heat-seal press | Garments and fabrics that tolerate heat |
| Sew-on (plain) backing | No application required | Permanent fixing, leather, technical fabrics |
| Hook-and-loop (velcro) | Adhesive application | Tactical gear, removable patches, uniforms with rotating insignia |
| Adhesive backing | Pressure-sensitive adhesive applicator | Temporary application, smooth surfaces |
| Plain backing | None | Customer applies own backing |
Digitising Studio
The digitising studio sits alongside production. Digitisers convert customer artwork into machine-readable production files: stitch files for embroidery, weave files for woven patches, mould files for PVC, and colour-corrected output files for printed patches.
Software used:
- Commercial embroidery digitising software (Wilcom, Pulse, Tajima DG/ML)
- Weave-pattern preparation software
- Standard vector design tools (Adobe Illustrator, CorelDRAW)
- Colour management software for Pantone matching
Digitising is included free on every order. The studio also creates artwork from scratch when customers supply sketches, descriptions or low-resolution reference images.
Quality Control Equipment
The QC bay uses physical and visual inspection tools to check every batch before dispatch.
QC checks performed:
- Stitch tension test (embroidery and chenille)
- Pantone match verification under standard daylight lamps
- Dimensional measurement (callipers)
- Border consistency inspection
- Backing adhesion test (iron-on and adhesive)
- Wash-fastness sampling (random batch checks)
Patches that fail QC are reworked or replaced before the batch ships. The workshop operates a zero-defect dispatch policy.
Equipment Maintenance
A dedicated maintenance team services the production equipment to prevent downtime. Routine maintenance includes thread tension calibration on embroidery machines, mould cleaning on PVC stations, print head servicing on sublimation printers and laser alignment on the cutting system.
Scheduled maintenance runs outside production hours to keep customer-facing turnaround times consistent.
Production Capacity
The current equipment configuration supports:
- 24-hour proof turnaround on every order
- 5–10 working day production lead time for standard orders
- Same-day dispatch once production completes
- Capacity for orders from 1 patch to 10,000+ patches per order
For specific lead times on large or rush orders, contact the team via the contact page before placing the order.
Why Equipment Detail Matters
UK B2B customers, particularly schools, councils, uniformed services and procurement teams, require evidence of manufacturing capability before approving suppliers. This page documents the equipment that supports every claim Custom Iron On Patches makes about UK production, turnaround time and quality control.
For a guided visit to the Birmingham workshop, contact the team to arrange an appointment.