Custom Iron On Patches accepts vector files (.ai, .eps, .pdf, .svg) and high-resolution raster files (.png, .jpg, .psd at 300dpi minimum) for every patch order. The in-house design team prepares production-ready files from supplied artwork, sketches or descriptions. Free design support is included on every order, customers do not need finished artwork to start an order.
This page documents the file specifications, design considerations and common artwork issues for each patch type.
Quick Reference: Accepted File Formats
| Format | Type | Preferred? | Notes |
| .ai (Adobe Illustrator) | Vector | ✓ Preferred | Native vector format, fully editable |
| .eps | Vector | ✓ Preferred | Universal vector format |
| .pdf (vector) | Vector | ✓ Preferred | Must be vector-based, not raster-flattened |
| .svg | Vector | ✓ Accepted | Web vector format, fully scalable |
| .png | Raster | ✓ Accepted | 300dpi minimum at production size, transparent background preferred |
| .jpg | Raster | Accepted | 300dpi minimum at production size |
| .psd (Photoshop) | Layered raster | Accepted | High resolution required |
| Sketch / hand drawing | N/A | ✓ Accepted | Free design team will recreate as production file |
| Description only | N/A | ✓ Accepted | Free design team will create artwork from scratch |
Vector files are always preferred. Vector artwork can be scaled to any size without quality loss. Raster files (PNG, JPG) must be supplied at high enough resolution to print clearly at the patch size.
If finished artwork is not available, the free design team can create it from a sketch, a reference image or a written description.
Vector vs Raster – Why It Matters
The two file types fundamentally differ in how they store image data:
- Vector files store images as mathematical paths between points. They scale to any size without losing detail or quality. Vector files are the production-ready format for embroidery digitising, weaving, PVC moulding and clean printing.
- Raster files store images as a grid of coloured pixels. Scaling a raster file beyond its original resolution produces blurred or pixelated output.
For custom patch production, vector files allow:
- Clean line definition for stitch paths (embroidery)
- Accurate weave grid mapping (woven patches)
- Sharp mould-edge definition (PVC patches)
- High-resolution print output (printed patches)
If only a raster file is available (typical for logos, photographs and screen-captured images), the in-house design team redraws the artwork as a vector before production. This service is included free on every order.
Resolution Requirements (For Raster Files)
Raster files must meet minimum resolution at production size to produce clean output.
| Patch Size | Minimum Image Resolution |
| Up to 50mm | 750 × 750 pixels minimum |
| 50-75mm | 1,000 × 1,000 pixels minimum |
| 75-100mm | 1,250 × 1,250 pixels minimum |
| 100-150mm | 1,750 × 1,750 pixels minimum |
| 150-250mm | 2,500 × 2,500 pixels minimum |
| 250mm+ | 3,500 × 3,500 pixels minimum |
The general rule: aim for 300dpi at the final production size. A 75mm patch at 300dpi requires roughly 900 pixels per side; supplying 1,000 pixels minimum gives a margin for cropping and edge processing.
Files below the minimum resolution will be flagged at digitising stage. The team can either:
- Recreate the artwork as a vector (no extra charge), or
- Request a higher-resolution version from the customer
Colour Specifications
Patch colours are matched to Pantone references wherever possible. Pantone colours produce predictable thread, yarn, ink and PVC colour matches across batches.
Pantone Matching System
Custom Iron On Patches uses the Pantone Matching System (PMS) for thread, weave, ink and PVC colour reference. To specify exact colours:
- Provide Pantone codes in artwork (e.g. PMS 286C for navy blue, PMS 485C for red)
- List Pantone codes alongside the file if not embedded in the artwork
- For corporate brand colours, include the brand colour palette document if available
If Pantone codes are not provided, the design team will match colours visually from the artwork to the closest standard Pantone.
Colour Limits by Patch Type
| Patch Type | Practical Colour Limit | Notes |
| Embroidered | 9-12 colours practical maximum | Each colour requires a separate thread changeover |
| Woven | 8-10 colours practical maximum | Higher counts increase production cost |
| PVC | 4-6 colours practical for 2D | Each colour requires a separate mould layer |
| Printed | Unlimited (full CMYK + Pantone) | Best for photo-realistic and gradient designs |
| Chenille | 1-4 colours typical | Multi-colour chenille is technically demanding |
Designs above these limits are still accepted, but the team will recommend either:
- Simplification of the colour palette
- Switching to printed patches for unlimited colour
- Combination techniques (e.g. embroidered detail on a printed base)
Sizing and Dimensions
Patch dimensions are measured in millimetres at the patch’s longest edge (or diameter for circular patches).
| Patch Size | Use Case |
| 25-50mm | Small accent patches, fashion label patches, fine-detail logos |
| 50-75mm | Standard club patches, school house patches, name badges |
| 75-100mm | Standard chest patches, club crests, jacket patches |
| 100-150mm | Large back patches, varsity letters, statement designs |
| 150-250mm | Large back patches, club back rockers, banner patches |
| 250mm+ | Specialist large patches, banner panels |
Minimum Detail Sizes
For text and fine detail to render legibly, observe these minimums by patch type:
| Patch Type | Minimum Text Height | Minimum Line Thickness |
| Embroidered | 5mm (0.2 inches) | 1mm |
| Woven | 3mm (0.12 inches) | 0.5mm |
| PVC | 4mm (0.16 inches) | 1mm |
| Printed | 2mm (0.08 inches) | 0.3mm |
| Chenille | 12mm (0.5 inches) | 3mm (chenille has minimum chain stitch width) |
Designs with text or detail below these minimums will be flagged at digitising stage. The team will either scale the design appropriately or recommend an alternative patch type that supports the required detail.
Design Considerations by Patch Type
Different patch types render artwork differently. Understanding the production method helps customers prepare suitable artwork.
Embroidered Patches
Embroidery uses thread to fill design areas with stitches. Best for:
- Bold, simple designs with defined shapes
- Limited colour palettes (under 9 colours typical)
- Designs with clean outlines
- Text 5mm or larger
Embroidery does not handle well:
- Photo-realistic gradients (no smooth colour transitions)
- Very small text (under 5mm)
- Fine line detail (under 1mm)
- Designs with hundreds of colour transitions
For complex multi-colour or photo-based designs, printed patches or woven patches typically produce better results.
Woven Patches
Weaving uses fine thread to produce the design itself, achieving higher detail than embroidery. Best for:
- Fine-detail logos with small text
- Corporate logos with thin lines
- Designs at small sizes (under 75mm)
- Designs with up to 8 colours
Woven patches do not produce a textured raised-thread appearance, the surface is smooth and flat.
PVC Patches
PVC patches are moulded from liquid PVC compound. Best for:
- Outdoor and weather-resistant applications
- 2D and 3D raised designs
- Bold, defined shapes
- Limited colour palettes
PVC patches require a mould per design (one-off cost £45-£85). Once the mould is made, repeat orders use the same mould.
Printed Patches
Dye-sublimation printing reproduces full-colour, photo-realistic and gradient designs. Best for:
- Photographs or photo-style images
- Complex multi-colour designs
- Smooth colour gradients
- Designs that would lose detail in embroidery or weaving
Printed patches use a polyester base fabric and produce a flat smooth surface.
Chenille Patches
Chain-stitch chenille creates a soft tufted texture. Best for:
- Varsity and letterman jackets
- School and university crests
- Sports club patches with bold lettering
Chenille requires bold, simple designs with strong shapes and limited colours. Detail under 12mm typically does not render in chenille.
Common Artwork Problems
The most common issues with submitted artwork:
1. Low-Resolution Logos
The most common issue. Logos pulled from websites are typically 72dpi (web resolution) and too low for clean production.
Fix: the design team redraws the logo as a vector. Free service.
2. Photographs Submitted for Embroidery
Customers sometimes submit photographs of designs they want embroidered. Embroidery cannot reproduce photographic detail, too many colour transitions, too much fine detail.
Fix: the team either recommends switching to printed patches, or prepares a stylised stitch-friendly version of the photograph. Free service.
3. Fonts Not Outlined
Vector files with live fonts may not display correctly if the recipient does not have the font installed.
Fix: customer should convert text to outlines/curves before submitting (in Illustrator: Type → Create Outlines). The design team can also handle this, flag the issue at quote stage.
4. Tiny Detail in Large Designs
Designs with very thin lines or tiny text relative to the overall design may not render in the chosen patch type.
Fix: the team simplifies fine detail or recommends a patch type that supports finer rendering (woven or printed).
5. Wrong Colour Mode
Some files are submitted in RGB (screen) colour mode rather than CMYK or Pantone. RGB colours often shift when converted for production printing.
Fix: the design team handles colour mode conversion. For brand-critical colours, customers should specify Pantone codes alongside the artwork.
Free Design Service – What’s Included
Custom Iron On Patches includes free design support on every order. This covers:
- Logo recreation – redrawing an existing logo as a clean vector file
- Sketch-to-design – converting a hand-drawn sketch into production-ready artwork
- Concept-to-design – creating original artwork from a written description
- File format conversion – converting raster files to vector
- Resolution improvement – recreating low-resolution files at production resolution
- Colour mode conversion – RGB to Pantone matching
- Font outlining – converting live fonts to outlined vector
- Proof revisions – unlimited revisions until the customer approves the proof
There is no extra charge for any of the above. The £70 minimum order value covers all design work for a single design.
For multi-design orders (multiple distinct patch designs in one order), each design has its own design and digitising work, quoted at quote stage.
Submitting Artwork
Artwork can be submitted via three channels:
- Quote form upload, attach files directly to the quote request form (multiple files supported, up to 25MB)
- Email, send files to [email protected] with the order reference or quote number
- File transfer service, for files larger than 25MB, use WeTransfer, Google Drive or Dropbox and share the link via email
Acceptable artwork submission formats are listed in the Quick Reference table at the top of this page.
Frequently Asked Artwork Questions
What file format is best for custom patches?
Vector files (.ai, .eps, .pdf, .svg) are always preferred because they scale to any size without quality loss. Raster files (.png, .jpg) are accepted if supplied at 300dpi minimum at production size. If only low-resolution artwork is available, the free in-house design team will recreate it as a vector.
Can I submit a logo from my website?
Logos pulled from websites are typically 72dpi and too low for clean patch production. The design team will redraw the logo as a high-resolution vector at no extra charge. There is no need to find a higher-resolution version before submitting.
What if I don’t have any artwork?
Free design support is included on every order. Customers can supply a sketch, a reference image, or simply describe the design. The design team creates the artwork from scratch, returns a proof within 24 hours and revises until approved.
What resolution do my files need to be?
Aim for 300dpi at the final patch size. For a 75mm patch, this means roughly 900 × 900 pixels minimum. Vector files have no resolution requirement and are always preferred.
How many colours can a custom patch have?
Embroidered and woven patches handle up to 8-10 colours practically. PVC patches handle 4-6 colours per 2D design. Printed patches handle unlimited colours, including full-colour photographs and gradients. Chenille patches handle 1-4 colours typical.
Should I supply Pantone references?
Yes, where colour accuracy matters. Pantone codes (e.g. PMS 286C) ensure exact thread, yarn, ink or PVC colour matches across batches. If Pantone codes are not provided, the design team matches colours visually from the artwork.
What’s the minimum text size on a custom patch?
Embroidered: 5mm minimum text height. Woven: 3mm minimum. Printed: 2mm minimum. PVC: 4mm minimum. Chenille: 12mm minimum. Smaller text may render but legibility is not guaranteed.
Do I need to outline fonts in vector files?
It helps. Outlined fonts (Type → Create Outlines in Illustrator) ensure text displays correctly without the original font installed. If fonts are not outlined, the design team will convert them, flag at quote stage if unsure.
Can you create custom artwork from scratch?
Yes. Free design support is included on every order. The team creates artwork from sketches, descriptions, reference images or brand briefs. Original design is included in the £70 minimum order value.
What happens if my artwork doesn’t meet the requirements?
The design team flags the issue at digitising stage. In most cases the team can fix the issue at no extra charge, recreate as vector, improve resolution, simplify detail, switch patch type recommendation. The customer is informed before any production work begins.
Get Started
To submit artwork or request a quote:
- Request a free quote and upload artwork
- Email: [email protected]
- Phone: 07746 501247
For pricing detail, see the pricing guide. For the full ordering process, see how to order custom patches.